U.S. patent application number 11/948669 was filed with the patent office on 2008-06-12 for olefin block compositions for stretch fabrics with wrinkle resistance.
This patent application is currently assigned to Dow Global Technologies Inc.. Invention is credited to Hongyu Chen, Yuen-Yuen D. Chiu, Tong Gao, Shih-Yaw Lai, Alberto Lora Lamia, Jerry Chien Ting Wang.
Application Number | 20080138599 11/948669 |
Document ID | / |
Family ID | 39272919 |
Filed Date | 2008-06-12 |
United States Patent
Application |
20080138599 |
Kind Code |
A1 |
Gao; Tong ; et al. |
June 12, 2008 |
OLEFIN BLOCK COMPOSITIONS FOR STRETCH FABRICS WITH WRINKLE
RESISTANCE
Abstract
Compositions having good wrinkle resistance and other properties
when made into garments an be made from an ethylene multi-block
copolymers. The resulting fabrics and garments often have good
chemical resistance, heat-resistances, and are dimensionally
stable.
Inventors: |
Gao; Tong; (Singapore,
SG) ; Chen; Hongyu; (Lake Jackson, TX) ;
Lamia; Alberto Lora; (Trivero, IT) ; Chiu; Yuen-Yuen
D.; (Pearland, TX) ; Wang; Jerry Chien Ting;
(Taichung, TW) ; Lai; Shih-Yaw; (Pearland,
TX) |
Correspondence
Address: |
JONES DAY / DOW
717 TEXAS, SUITE 3300
HOUSTON
TX
77002
US
|
Assignee: |
Dow Global Technologies
Inc.
Midland
MI
|
Family ID: |
39272919 |
Appl. No.: |
11/948669 |
Filed: |
November 30, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60868020 |
Nov 30, 2006 |
|
|
|
Current U.S.
Class: |
428/221 |
Current CPC
Class: |
Y10T 442/3252 20150401;
C08L 1/02 20130101; C08L 23/08 20130101; D01F 6/30 20130101; D01F
8/06 20130101; Y10T 442/3244 20150401; Y10T 442/444 20150401; Y10T
442/3146 20150401; C08F 295/00 20130101; C08L 53/00 20130101; C08L
23/08 20130101; Y10T 428/249921 20150401; C08L 23/0815 20130101;
C08F 297/086 20130101; Y10T 442/3008 20150401; D01F 6/46 20130101;
Y10T 442/413 20150401; C08L 2205/16 20130101; C08L 23/10 20130101;
C08L 2666/26 20130101; C08L 53/00 20130101; C08F 4/64193 20130101;
C08L 2666/24 20130101; C08L 2666/26 20130101; C08L 2666/26
20130101; C08L 23/0815 20130101; C08L 1/02 20130101; C08F 10/00
20130101; C08F 10/00 20130101 |
Class at
Publication: |
428/221 |
International
Class: |
B32B 7/02 20060101
B32B007/02 |
Claims
1. A stretch fabric capable of being subjected to a wrinkle-free
treatment comprising: (A) an ethylene/.alpha.-olefin interpolymer,
wherein the ethylene.alpha.-olefin interpolymer before crosslinking
is characterized by one or more of the following characteristics:
(1) an average block index greater than zero and up to about 1.0
and a molecular weight distribution, Mw/Mn, greater than about 1.3;
or (2) at least one molecular fraction which elutes between
40.degree. C. and 130.degree. C. when fractionated using TREF,
characterized in that the fraction has a block index of at least
0.5 and up to about 1; or (3) an Mw/Mn from about 1.7 to about 3.5,
at least one melting point, Tm, in degrees Celsius, and a density,
d, in grams/cubic centimeter, wherein the numerical values of Tm
and d correspond to the relationship:
T.sub.m>-2002.9+4538.5(d)-2422.2(d).sup.2; or (4) an Mw/Mn from
about 1.7 to about 3.5, and a heat of fusion, .DELTA.H in J/g, and
a delta quantity .DELTA.T, in degrees Celsius defined as the
temperature difference between the tallest DSC peak and the tallest
CRYSTAF peak, wherein the numerical values of .DELTA.T and .DELTA.H
have the following relationships:
.DELTA.T>-0.1299(.DELTA.H)+62.81 for .DELTA.H greater than zero
and up to 130 J/g, .DELTA.T.gtoreq.48.degree. C. for .DELTA.H
greater than 130 J/g, wherein the CRYSTAF peak is determined using
at least 5 percent of the cumulative polymer, and if less than 5
percent of the polymer has an identifiable CRYSTAF peak, then the
CRYSTAF temperature is 30.degree. C.; or (5) an elastic recovery,
Re, in percent at 300 percent strain and 1 cycle measured with a
compression-molded film of the ethylene/.alpha.-olefin
interpolymer, and has a density, d, in grams/cubic centimeter,
wherein the numerical values of Re and d satisfy the following
relationship when ethylene/.alpha.-olefin interpolymer is
substantially free of a cross-linked phase: Re>1481-1629(d); or
(6) a molecular fraction which elutes between 40.degree. C. and
130.degree. C. when fractionated using TREF, characterized in that
the fraction has a molar comonomer content of at least 5 percent
higher than that of a comparable random ethylene interpolymer
fraction eluting between the same temperatures, wherein said
comparable random ethylene interpolymer has the same comonomer(s)
and has a melt index density, and molar comonomer content (based on
the whole polymer) within 10 percent of that of the
ethylene/.alpha.-olefin interpolymer; or (2) a storage modulus at
25.degree. C., G'(25.degree. C.), and a storage modulus at
100.degree. C., G'(100.degree. C.), wherein the ratio of
G(25.degree. C.) to G'(100.degree. C.) is in the range of about 1:1
to about 9:1; and (B) at least one other material; wherein the
fabric has a stretch of at least 8 percent measured according to
ASTM D3107, and wherein the fabric has a durable press rating of at
least 3.0 after 5 times washing using AATCC-124 or Marks and
Spencer P134 after said fabric is subjected to a wrinkle-free
treatment.
2. The fabric of claim 1 wherein the other material is selected
from the group consisting of cellulose, cotton, flax, ramie, rayon,
viscose, hemp, wool, silk, linen, bamboo, tencel, viscose, mohair,
polyester, polyamide, polypropylene, and mixtures thereof.
3. The fabric of claim 1 wherein cellulose comprises 60 to 97
percent by weight of the fabric.
4. The fabric of claim 3 wherein cellulose comprises at least 90
percent by weight of the fabric.
5. The fabric of claim 3 wherein the cellulose comprises
cotton.
6. The fabric of claim 1 wherein the ethylene/.alpha.-olefin
interpolymer comprises 2 percent to 10 percent by weight of the
fabric.
7. The fabric of claim 1 wherein the fabric tear strength is at
least 1.5 pounds as measured according to ASTM P1424 or at least
1.1 pounds as measured by Marks and Spencer P11.
8. The fabric of claim 1 wherein the ethylene/.alpha.-olefin
interpolymer is characterized by a density of from about 0.865 to
about 0.92 g/cm.sup.3 (ASTM D 792) and a melt index of from about
0.1 to about 10 g/10 minutes before any crosslinking.
9. The fabric of claim 1 wherein the ethylene/.alpha.-olefin
interpolymer is in the form of one or more fibers comprising the
reaction product of ethylene/.alpha.-olefin interpolymer and at
least one crosslinking agent and wherein said fiber has a denier of
from about 1 denier to about 180 denier.
10. The fabric of claim 1 wherein the ethylene/.alpha.-olefin
interpolymer is in the form of one or more fibers comprising the
reaction product of ethylene/.alpha.-olefin interpolymer and at
least one crosslinking agent and wherein said one or more fibers
comprise from about 1 to about 30% by weight of the fabric.
11. The fabric of claim 10 wherein the fabric is a knit fabric.
12. The fabric of claim 1 wherein the ethylene/.alpha.-olefin
interpolymer is in the form of one or more fibers comprising the
reaction product of ethylene/.alpha.-olefin interpolymer and at
least one crosslinking agent and wherein said one or more fibers
comprise from about 1 to about 10% by weight of the fabric.
13. The fabric of claim 12 wherein the fabric is a woven
fabric.
14. The fabric of claim 1 wherein the ethylene/.alpha.-olefin
interpolymer is in the form of one or more fibers comprising the
reaction product of ethylene/.alpha.-olefin interpolymer and at
least one crosslinking agent wherein said one or more fibers
comprise a gel content of at least about 10% by weight.
15. The fabric of claim 1 wherein the fabric can be stretched in
two dimensions.
16. The fabric of claim 1 wherein the fabric comprises permanent
bonds rendering it relatively wrinkle-free.
17. The fabric of claim 15 wherein the fabric has a durable press
rating of at least 3.0 after 5 times washing using AATCC-124 or
Marks and Spencer P134.
18. The fabric of claim 1 wherein the fabric retains its
dimensional stability after wrinkle free treatment.
19. The fabric of claim 1 wherein the other material comprises
keratin and wherein said fabric has been rendered washable and
wrinkle-free without ironing.
20. The fabric of claim 1 wherein the ethylene .alpha.-olefin
interpolymer is in the form of one or more fibers comprising the
reaction product of ethylene/.alpha.-olefin interpolymer and at
least one crosslinking agent, wherein the other material comprises
keratin, and wherein said fabric has been rendered washable and
wrinkle-free without ironing.
21. The fabric of claim 1, wherein the fabric is such that any
creases formed in the fabric will be substantially retained after
washing.
22. A garment comprising the fabric of claim 1.
23. The garment of claim 22 wherein the garment has a crease
retention rating of at least 3.0 after 5 times washing using
AATCC-143-1996.
24. The fabric of claim 1 wherein the ratio of percent growth to
percent stretch is from about 0.05 to about 0.5.
25. The fabric of claim 1 which comprises elastic fibers comprised
of a polymer selected from the group consisting of polybutylene
terephthalate, spandex, poly ethylene terephthalate),
polytrimethylene terephthalate), and mixtures thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] For purposes of United States patent practice, the contents
of U.S. Provisional Application No. 60/868,020 filed on Nov. 30,
2006, PCT Application No. PCT/US2005/008917 (Dow 63558D), filed on
Mar. 17, 2005, which in turn claims priority to U.S. Provisional
Application No. 60/553,906, filed Mar. 17, 2004 are herein
incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates to improved compositions for stretch
fabrics with wrinkle resistance.
BACKGROUND OF THE INVENTION
[0003] As textile articles such as fabric, linens and garments are
used, wrinkles appear on the surface. In the case of garments,
particularly cellulosic-based garments, wear and especially the
laundering of the garments causes wrinkles which results in a
generally undesirable appearance. To remove the wrinkles, consumers
of the garment use a variety of methods including ironing, pressing
and even closely monitored tumble drying. Frequent or difficult
wrinkling leads to consumer dissatisfaction. Manufacturers and
designers of textile articles have sought to give the articles a
durable press such that the articles exhibit the ability to avoid
wrinkle formation and/or the ability to quickly remove the wrinkles
with minimal effort.
[0004] Typical wrinkle-free treatments (also sometimes referred to
as a durable press coating) include imparting hydrogen or covalent
bonds that do not significantly degrade when the fabric is cleaned
in some fashion, typically by hand or machine washing. In this
sense the bonds are permanent and the fabric is relatively
wrinkle-free during its useful life. Typical durable press coatings
often involve the application of a chemical coating to the surface
of the fabric, i.e., textile. These coatings usually include a
cross-linking agent and catalyst such that cross-links form between
the agent and a material, e.g. cellulose, in the fibers. The
crosslinks not only provide wrinkle resistance but may also improve
dimensional stability, increase fabric smoothness and improve
crease retention.
[0005] The chemical coatings which are often currently used to
impart wrinkle resistance to a textile, are relatively harsh and
unsuitable for many fabrics. There is a continuing need for
stretchable fabric that is capable of being subjected to
wrinkle-free treatment.
SUMMARY OF THE INVENTION
[0006] Provided herein are textile articles comprising stretchable
fabrics that have a combination of desirable properties including
one or more of the following: dimensional stability, heat-set
properties, capability to be made wrinkle-free, stretchable in one
or both dimensions, capability to be made into garments that retain
creases, chemical, heat, and abrasion resistant, tenacity, etc. In
one aspect, such fabrics is able to withstand hand or machine
washing without significantly degrading one or more of the
aforementioned properties.
[0007] Stretchable fabric or stretch fabric compositions provided
herein have a balanced combination of desirable properties. The
fabric provided herein is typically a stretch fabric capable of
being subjected to a wrinkle-free treatment. The stretch fabric
provided herein comprises:
[0008] (A) an ethylene/.alpha.-olefin interpolymer, wherein the
ethylene/.alpha.-olefin interpolymer has one or more of the
following characteristics: [0009] (1) an average block index
greater than zero and up to about 1.0 and a molecular weight
distribution, Mw/Mn, greater than about 1.3; or [0010] (2) at least
one molecular fraction which elutes between 40.degree. C. and
130.degree. C. when fractionated using, TREF, characterized in that
the fraction has a block index of at least 0.5 and up to about 1;
or [0011] (3) an Mw/Mn from about 1.7 to about 3.5, at least one
melting point, Tm, in degrees Celsius, and a density, d, in
grams/cubic centimeter, wherein the numerical values of Tm and d
correspond to the relationship:
[0011] T.sub.m>-2002.9+4538.5(d)-2422.2(d).sup.2; or [0012] (4)
an Mw/Mn from about 1.7 to about 3.5, and is characterized by a
heat of fusion, .DELTA.H in J/g, and a delta quantity, .DELTA.T, in
degrees Celsius defined as the temperature difference between the
tallest DSC peak and the tallest CRYSTAF peak, wherein the
numerical values of .DELTA.T and .DELTA.H have the following
relationships:
[0012] .DELTA.T>-0.1299(.DELTA.H)+62.81 for .DELTA.H greater
than zero and up to 130 J/g,
.DELTA.T.gtoreq.48.degree. C. for .DELTA.H greater than 130
.mu.J/g,
[0013] wherein the CRYSTAF peak is determined using at least 5
percent of the cumulative polymer, and if less than 5 percent of
the polymer has an identifiable CRYSTAF peak, then the CRYSTAF
temperature is 30.degree. C.; or [0014] (5) an elastic recovery,
Re, in percent at 300 percent strain and 1 cycle measured with a
compression-molded film of the ethylene/.alpha.-olefin
interpolymer, and has a density, d, in grams/cubic centimeter,
wherein the numerical values of Re and d satisfy the following
relationship when ethylene/.alpha.-olefin interpolymer is
substantially free of a cross-linked phase:
[0015] Re>1481-1629(d); or [0016] (6) a molecular fraction which
elutes between 40.degree. C. and 130.degree. C. when fractionated
using TREF, characterized in that the fraction has a molar
comonomer content of at least 5 percent higher than that of a
comparable random ethylene interpolymer fraction eluting between
the same temperatures, wherein said comparable random ethylene
interpolymer has the same comonomers(s) and has a melt index,
density, and molar comonomer content (based on the whole polymer)
within 10 percent of that of the ethylene/.alpha.-olefin
interpolymer; or [0017] (7) a storage modulus at 25.degree. C.
G'(25.degree. C.), and a storage modulus at 100.degree. C.,
G'(100.degree. C.), wherein the ratio of G'(25.degree. C.) to
G'(100.degree. C.) is in the range of about 1:1 to about 9:1,
and
[0018] (B) at least one other material;
[0019] wherein the fabric has a stretch of at least 8 percent
measured according to ASTM D3107 and wherein the fabric has a
durable press rating of at least 3.0 after 5 times washing using
AATCC-124 or Marks and Spencer P134 after said fabric is subjected
to a wrinkle-free treatment.
[0020] The ethylene/.alpha.-olefin interpolymer characteristics (1)
through (7) above are given with respect to the
ethylene/.alpha.-olefin interpolymer before any significant
crosslinking, i.e., before crosslinking. The
ethylene/.alpha.-olefin interpolymers useful in the present
invention may or may not be crosslinked depending upon the desired
properties. By using characteristics (1) through (7) as measured
before crosslinking is not meant to suggest that the interpolymer
is required or not required to be crosslinked only that the
characteristic is measured with respect to the interpolymer without
significant crosslinking. Crosslinking may or may not change each
of these properties depending upon the specific polymer and degree
of crosslinking.
[0021] In certain embodiments, the ethylene/.alpha.-olefin
interpolymer in the stretch fabric provided herein is in form of an
elastic fiber.
[0022] The other material is often selected from the group
consisting of cotton, flax, ramie, rayon, viscose, hemp, wool,
silk, linen, bamboo, tencel, viscose, mohair, polyester, polyamide,
polypropylene, other cellulosic, protein, or synthetic fibers, as
well as, mixtures thereof. In one embodiment, the other material
comprises cellulose, wool, or mixtures thereof. In one embodiment
the fabric is knitted or woven.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows the melting point/density relationship for the
inventive polymers (represented by diamonds) as compared to
traditional random copolymers (represented by circles) and
Ziegler-Natta copolymers (represented by triangles).
[0024] FIG. 2 shows plots of delta DSC-CRYSTAF as a function of DSC
Melt Enthalpy for various polymers. The diamonds represent random
ethylene/octene copolymers; the squares represent polymer examples
1-4; the triangles represent polymer examples 5-9; and the circles
represent polymer examples 10-19. The "X" symbols represent polymer
examples A*-F*.
[0025] FIG. 3 shows the effect of density on elastic recovery for
unoriented films made from inventive interpolymers (represented by
the squares and circles) and traditional copolymers (represented by
the triangles which are various Dow AFFINITY.RTM. polymers). The
squares represent inventive ethylene/butene copolymers; and the
circles represent inventive ethylene/octene copolymers.
[0026] FIG. 4 is a plot of octene content of TREF fractionated
ethylene/1-octene copolymer fractions versus TREF elution
temperature of the fraction for the polymer of Example 5
(represented by the circles) and comparative polymers E and F
(represented by the "X" symbols). The diamonds represent
traditional random ethylene/octene copolymers.
[0027] FIG. 5 is a plot of octene content of TREE fractionated
ethylene 1-octene copolymer fractions versus TREF elution
temperature of the fraction for the polymer of Example 5 (curve 1)
and for comparative F (curve 2). The squares represent Example F*;
and the triangles represent Example 5.
[0028] FIG. 6 is a graph of the log of storage modulus as a
function of temperature for comparative ethylene/1-octene copolymer
(curve 2) and propylene/ethylene-copolymer (curve 3) and for two
ethylene 1-octene block copolymers of the invention made with
differing quantities of chain shuttling agent (curves 1).
[0029] FIG. 7 shows a plot of TMA (1 mm) versus flex modulus for
some inventive polymers (represented by the diamonds), as compared
to some known polymers. The triangles represent various Dow
VERSIFY.RTM. polymers; the circles represent various random
ethylene/styrene copolymers; and the squares represent various Dow
AFFINITY.RTM. polymers.
[0030] FIG. 8 shows a plot of e-beam radiation versus percent
crosslinking for an olefin block copolymer.
DETAILED DESCRIPTION OF THE INVENTION
General Definitions
[0031] "Polymer" means a polymeric compound prepared by
polymerizing monomers, whether of the same or a different type. The
generic term "polymer" embraces the terms "homopolymer,"
"copolymer," "terpolymer" as well as "interpolymer."
[0032] "Interpolymer" means a polymer prepared by the
polymerization of at least two different types of monomers. The
generic term "interpolymer" includes the term "copolymer" (which is
usually employed to refer to a polymer prepared from two different
monomers) as well as the term "terpolymer" (which is usually
employed to refer to a polymer prepared from three different types
of monomers). It also encompasses polymers made by polymerizing
four or more types of monomers.
[0033] The term "ethylene/.alpha.-olefin interpolymer" generally
refers to polymers comprising ethylene and an .alpha.-olefin having
3 or more carbon atoms. Preferably, ethylene comprises the majority
mole fraction of the whole polymer, i.e., ethylene comprises at
least about 50 mole percent of the whole polymer. More preferably
ethylene comprises at least about 60 mole percent, at least about
70 mole percent, or at least about 80 mole percent, with the
substantial remainder of the whole polymer comprising at least one
other comonomer that is preferably an .alpha.-olefin having 3 or
more carbon atoms. For many ethylene/octene copolymers, the
preferred composition comprises an ethylene content greater than
about 80 mole percent of the whole polymer and an octene content of
from about 10 to about 15, preferably from about 15 to about 20
mole percent of the whole polymer. In some embodiments, the
ethylene/b-olefin interpolymers do not include those produced in
low yields or in a minor amount or as a by-product of a chemical
process. While the ethylene/.alpha.-olefin interpolymers can be
blended with one or more polymers, the as-produced
ethylene/.alpha.-olefin interpolymers are substantially pure and
often comprise a major component of the reaction product of a
polymerization process.
[0034] The ethylene/.alpha.-olefin interpolymers comprise ethylene
and one or more copolymerizable .alpha.-olefin comonomers in
polymerized form, characterized by multiple blocks or segments of
two or more polymerized monomer units differing in chemical or
physical properties. That is, the ethylene/.alpha.-olefin
interpolymers are block interpolymers, preferably multi-block
interpolymers or copolymers. The terms interpolymer and copolymers
are used interchangeably herein. In some embodiments, the
multi-block copolymer can be represented by the following
formula:
(AB).sub.n
where n is at least 1, preferably an integer greater than 1, such
as 2, 3, 4, 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 100, or
higher, "A" represents a hard block or segment and "B" represents a
soft block or segment. Preferably, As and Bs are linked in a
substantially linear fashion, as opposed to a substantially
branched or substantially star-shaped fashion. In other
embodiments, A blocks and B blocks are randomly distributed along
the polymer chain. In other words, the block copolymers usually do
not have a structure as follows.
AAA-AA-BBB-BB
[0035] In still other embodiments, the block copolymers do not
usually have a third type of block, which comprises different
comonomer(s). In yet other embodiments, each of block A and block B
has monomers or comonomers substantially randomly distributed
within the block.
[0036] In other words, neither block A nor block B comprises two or
more sub-segments (or sub-blocks) of distinct composition, such as
a tip segment, which has a substantially different composition than
the rest of the block.
[0037] The multi-block polymers typically comprise various amounts
of "hard" and "soft" segments. "Hard" segments refer to blocks of
polymerized units in which ethylene is present in an amount greater
than about 95 weight percent, and preferably greater than about 98
weight percent based on the weight of the polymer. In other words,
the comonomer content (content of monomers other than ethylene) in
the hard segments is less than about 5 weight percent, and
preferably less than about 2 weight percent based on the weight of
the polymer. In some embodiments, the hard segments comprises all
or substantially all ethylene. "Soft" segments, on the other hand,
refer to blocks of polymerized units in which the comonomer content
(content of monomers other than ethylene) is greater than about 5
weight percent, preferably greater than about 8 weight percent,
greater than about 10 weight percent, or greater than about 15
weight percent based on the weight of the polymer. In some
embodiments, the comonomer content in the soft segments can be
greater than about 20 weight percent, greater than about 25 weight
percent, greater than about 30 weight percent, greater than about
35 weight percent, greater than about 40 weight percent, greater
than about 45 weight percent, greater than about 50 weight percent,
or greater than about 60 weight percent.
[0038] The soft segments can often be present in a block
interpolymer from about 1 weight percent to about 99 weight percent
of the total weight of the block interpolymer, preferably from
about 5 weight percent to about 95 weight percent, from about 10
weight percent to about 90 weight percent, from about 15 weight
percent to about 85 weight percent, from about 20 weight percent to
about 80 weight percent, from about 25 weight percent to about 75
weight percent, from about 30 weight percent to about 70 weight
percent, from about 35 weight percent to about 65 weight percent,
from about 40 weight percent to about 60 weight percent, or from
about 45 weight percent to about 55 weight percent of the total
weight of the block interpolymer. Conversely, the hard segments can
be present in similar ranges. The soft segment weight percentage
and the hard segment weight percentage can be calculated based on
data obtained from DSC or NMR. Such methods and calculations are
disclosed in a concurrently filed U.S. patent application Ser. No.
11/376,835, Attorney Docket No. 385063-999558, entitled
"Ethylene/.alpha.-Olefin Block Interpolymers", filed on Mar. 15,
2006, in the name of Colin L. P. Shan, Lonnie Hazlitt, et. al. and
assigned to Dow Global Technologies Inc., the disclosure of which
is incorporated by reference herein in its entirety.
[0039] The term "crystalline" if employed, refers to a polymer that
possesses a first order transition or crystalline melting point
(Tm) as determined by differential scanning calorimetry (DSC) or
equivalent technique. The term may be used interchangeably with the
term "semicrystalline". The term "amorphous" refers to a polymer
lacking a crystalline melting point as determined by differential
scanning calorimetry (DSC) or equivalent technique.
[0040] The term "multi-block copolymer" or "segmented copolymer"
refers to a polymer comprising two or more chemically distinct
regions or segments (referred to as "blocks") preferably joined in
a linear manner, that is, a polymer comprising chemically
differentiated units which are joined end-to-end with respect to
polymerized ethylenic functionality, rather than in pendent or
grafted fashion. In a preferred embodiment, the blocks differ in
the amount or type of comonomer incorporated therein, the density,
the amount of crystallinity, the crystallite size attributable to a
polymer of such composition, the type or degree of tacticity
(isotactic or syndiotactic), regio-reularity or regio-irregularity,
the amount of branching, including long chain branching or
hyper-branching, the homogeneity, or any other chemical or physical
property. The multi-block copolymers are characterized by unique
distributions of both polydispersity index (PDI or Mw/Mn), block
length distribution, and/or block number distribution due to the
unique process making of the copolymers. More specifically, when
produced in a continuous process, the polymers desirably possess
PDI from 1.7 to 2.9, preferably from 1.8 to 2.5, more preferably
from 1.8 to 2.2, and most preferably from 1.8 to 2.1. When produced
in a batch or semi-batch process, the polymers possess PDI from 1.0
to 2.9, preferably from 1.3 to 2.5, more preferably from 1.4 to
2.0, and most preferably from 1.4 to 1.8.
[0041] In the following description, all numbers disclosed herein
are approximate values, regardless whether the word "about" or
"approximate" is used in connection therewith. They may vary by 1
percent, 2 percent, 5 percent, or, sometimes, 10 to 20 percent.
Whenever a numerical range with a lower limit, R.sup.L and an upper
limit, R.sup.U, is disclosed, any number falling within the range
is specifically disclosed. In particular, the following numbers
within the range are specifically disclosed:
R=R.sup.L+k*(R.sup.U-R.sup.L), wherein k is a variable ranging from
1 percent to 100 percent with a 1 percent increment, i.e., k is 1
percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50
percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97
percent, 98 percent, 99 percent, or 100 percent. Moreover, any
numerical range defined by two R numbers as defined in the above is
also specifically disclosed.
[0042] (A) Ethylene/.alpha.-olefin Interpolymers
[0043] The ethylene/.alpha.-olefin interpolymers used in
embodiments of the invention (also referred to as "inventive
interpolymer" or "inventive polymer") comprise ethylene and one or
more copolymerizable .alpha.-olefin comonomers in polymerized form,
characterized by multiple blocks or segments of two or more
polymerized monomer units differing in chemical or physical
properties (block interpolymer), preferably a multi-block
copolymer. The ethylene/.alpha.-olefin interpolymers are
characterized by one or more of the aspects described as
follows.
[0044] In one aspect, the ethylene/.alpha.-olefin interpolymers
used in embodiments of the invention have a M.sub.w/M.sub.n from
about 1.7 to about 3.5 and at least one melting point, T.sub.m, in
degrees Celsius and density, d, in grams/cubic centimeter, wherein
the numerical values of the variables correspond to the
relationship:
T.sub.m>-2002.9+4538.5(d)-2422.2(d).sup.2, and preferably
T.sub.m.gtoreq.-6288.1-13141(d)-6720.3(d).sup.2, and more
preferably
T.sub.m.gtoreq.858.91-1825.3(d)+1112.8(d).sup.2.
[0045] Such melting point/density relationship is illustrated in
FIG. 1. Unlike the traditional random copolymers of
ethylene/.alpha.-olefins whose melting points decrease with
decreasing densities, the inventive interpolymers (represented by
diamonds) exhibit melting points substantially independent of the
density, particularly when density is between about 0.87 g/cc to
about 0.95 g/cc. For example, the melting point of such polymers
are in the range of about 110.degree. C. to about 130.degree. C.
when density ranges from 0.875 g/cc to about 0.945 g/cc. In some
embodiments, the melting point of such polymers are in the range of
about 115.degree. C. to about 125.degree. C. when density ranges
from 0.875 g/cc to about 0.945 g/cc.
[0046] In another aspect, the ethylene/.alpha.-olefin interpolymers
comprise, in polymerized form, ethylene and one or more
.alpha.-olefins and are characterized by a .DELTA.T, in degree
Celsius, defined as the temperature for the tallest Differential
Scanning Calorimetry ("DSC") peak minus the temperature for the
tallest Crystallization Analysis Fractionation ("CRYSTAF") peak and
a heat of fusion in J/g, .DELTA.H, and .DELTA.T and .DELTA.H
satisfy the following relationships:
.DELTA.T>-0.1299(.DELTA.H)+62.81, and preferably
.DELTA.T.gtoreq.-0.1299(.DELTA.H4)+64.38, and more preferably
.DELTA.T.gtoreq.-0.1299(.DELTA.H)+65.95,
for .DELTA.H up to 130 J/g. Moreover, .DELTA.T is equal to or
greater than 48.degree. C. for .DELTA.H greater than 130 J/g. The
CRYSTAF peak is determined using at least 5 percent of the
cumulative polymer (that is, the peak must represent at least 5
percent of the cumulative polymer), and if less than 5 percent of
the polymer has an identifiable CRYSTAF peak, then the CRYSTAF
temperature is 30.degree. C. and .DELTA.H is the numerical value of
the heat of fusion in J/g. More preferably, the highest CRYSTAF
peak contains at least 10 percent of the cumulative polymer. FIG. 2
shows plotted data for inventive polymers as well as comparative
examples. Integrated peak areas and peak temperatures are
calculated by the computerized drawing program supplied by the
instrument maker. The diagonal line shown for the random ethylene
octene comparative polymers corresponds to the equation
.DELTA.T=-0.1299 (.DELTA.H)+62.81.
[0047] In yet another aspect, the ethylene/.alpha.-olefin
interpolymers have a molecular fraction which elutes between
40.degree. C. and 130.degree. C. when fractionated using
Temperature Rising Elution Fractionation ("TREF"), characterized in
that said fraction has a molar comonomer content higher, preferably
at least 5 percent higher, more preferably at least 10 percent
higher, than that of a comparable random ethylene interpolymer
fraction eluting between the same temperatures, wherein the
comparable random ethylene interpolymer contains the same
comonomer(s), and has a melt index, density, and molar comonomer
content (based on the whole polymer) within 10 percent of that of
the block interpolymer. Preferably, the Mw/Mn of the comparable
interpolymer is also within 10 percent of that of the block
interpolymer and/or the comparable interpolymer has a total
comonomer content within 10 weight percent of that of the block
interpolymer.
[0048] In still another aspect, the ethylene/.alpha.-olefin
interpolymers are characterized by an elastic recovery, Re, in
percent at 300 percent strain and 1 cycle measured on a
compression-molded film of an ethylene/.alpha.-olefin interpolymer,
and has a density, d, in grams/cubic centimeter, wherein the
numerical values of Re and d satisfy the following relationship
when ethylene/.alpha.-olefin interpolymer is substantially free of
a cross-linked phase:
[0049] Re>1481-1629(d); and preferably
[0050] Re>1491-1629(d); and more preferably
[0051] Re>1501-1629(d); and even more preferably
[0052] Re.gtoreq.1511-1629(d).
[0053] FIG. 3 shows the effect of density on elastic recover for
unoriented films made from certain inventive interpolymers and
traditional random copolymers. For the same density, the inventive
interpolymers have substantially higher elastic recoveries.
[0054] In some embodiments, the ethylene/.alpha.-olefin
interpolymers have a tensile strength above 10 MPa, preferably a
tensile strength .gtoreq.11 MPa, more preferably a tensile strength
.gtoreq.13 MPa, and/or an elongation at break of at least 600
percent, more preferably at least 700 percent, highly preferably at
least 800 percent, and most highly preferably at least 900 percent
at a crosshead separation rate of 11 cm/minute.
[0055] In other embodiments, the ethylene/.alpha.-olefin
interpolymers have (1) a storage modulus ratio, G'(25.degree.
C.)/G'(100.degree. C.), of from 1 to 50, preferably from 1 to 20,
more preferably from 1 to 10; and/or (2) a 70.degree. C.
compression set of less than 80 percent, preferably less than 70
percent, especially less than 60 percent, less than 50 percent, or
less than 40 percent, down to a compression set of 0 percent.
[0056] In still other embodiments, the ethylene/.alpha.-olefin
interpolymers have a 70.degree. C. compression set of less than 80
percent, less than 70 percent, less than 60 percent, or less than
50 percent. Preferably, the 70.degree. C. compression set of the
interpolymers is less than 40 percent, less than 30 percent, less
than 20 percent, and may go down to about 0 percent.
[0057] In some embodiments, the ethylene/.alpha.-olefin
interpolymers have a heat of fusion of less than 85 .mu.J/g and or
a pellet blocking strength of equal to or less than 100
pounds/foot.sup.2 (4800 Pa), preferably equal to or less than 50
lbs/ft.sup.2 (2400 Pa), especially equal to or less than 5 lbs/ft
(240 Pa), and as low as 0 lbs/ft.sup.2 (0 Pa).
[0058] In other embodiments, the ethylene/.alpha.-olefin
interpolymers comprise, in polymerized form, at least 50 mole
percent ethylene and have a 70.degree. C. compression set of less
than 80 percent, preferably less than 70 percent or less than 60
percent, most preferably less than 40 to 50 percent and down to
close zero percent.
[0059] In some embodiments, the multi-block copolymers possess a
PDI fitting a Schultz-Flory distribution rather than a Poisson
distribution. The copolymers are further characterized as having
both a polydisperse block distribution and a polydisperse
distribution of block sizes and possessing a most probable
distribution of block lengths. Preferred multi-block copolymers are
those containing 4 or more blocks or segments including terminal
blocks. More preferably, the copolymers include at least 5, 10 or
20 blocks or segments including terminal blocks.
[0060] Comonomer content may be measured using any suitable
technique, with techniques based on nuclear magnetic resonance
("NMR") spectroscopy preferred. Moreover for polymers or blends of
polymers having relatively broad TREF curves, the polymer desirably
is first fractionated using TREF into fractions each having an
eluted temperature range of 10.degree. C. or less. That is, each
eluted fraction has a collection temperature window of 10.degree.
C. or less. Using this technique, said block interpolymers have at
least one such fraction having a higher molar comonomer content
than a corresponding fraction of the comparable interpolymer.
[0061] In another aspect, the inventive polymer is an olefin
interpolymer, preferably comprising ethylene and one or more
copolymerizable comonomers in polymerized form, characterized by
multiple blocks (i.e., at least two blocks) or segments of two or
more polymerized monomer units differing in chemical or physical
properties (blocked interpolymer), most preferably a multi-block
copolymer, said block interpolymer having a peak (but not just a
molecular fraction) which elutes between 40.degree. C. and
130.degree. C. (but without collecting and/or isolating individual
fractions), characterized in that said peak, has a comonomer
content estimated by infra-red spectroscopy when expanded using a
full width/half maximum (FWHM) area calculation, has an average
molar comonomer content higher, preferably at least 5 percent
higher, more preferably at least 10 percent higher, than that of a
comparable random ethylene interpolymer peak at the same elution
temperature and expanded using a full width/half maximum (FWHM)
area calculation, wherein said comparable random ethylene
interpolymer has the same comonomer(s) and has a melt index,
density, and molar comonomer content (based on the whole polymer)
within 10 percent of that of the blocked interpolymer. Preferably,
the Mw/Mn of the comparable interpolymer is also within 10 percent
of that of the blocked interpolymer and/or the comparable
interpolymer has a total comonomer content within 10 weight percent
of that of the blocked interpolymer. The full width/half maximum
(FWHM) calculation is based on the ratio of methyl to methylene
response area [CH.sub.3/CH.sub.2] from the ATREF infra-red
detector, wherein the tallest (highest) peak is identified from the
base line, and then the FWHM area is determined. For a distribution
measured using an ATREF peak, the FWHM area is defined as the area
under the curve between T.sub.1 and T.sub.2, where T.sub.1 and
T.sub.2 are points determined, to the left and right of the ATREF
peak, by dividing the peak height by two, and then drawing a line
horizontal to the base line, that intersects the left and right
portions of the ATREF curve. A calibration curve for comonomer
content is made using random ethylene/.alpha.-olefin copolymers,
plotting comonomer content from NMR versus FWHM area ratio of the
TREF peak. For this infra-red method, the calibration curve is
generated for the same comonomer type of interest. The comonomer
content of TREE peak of the inventive polymer can be determined by
referencing this calibration curve using its FWHM methyl:methylene
area ratio [CH.sub.3/CH.sub.2] of the TREF peak.
[0062] Comonomer content may be measured using any suitable
technique, with techniques based on nuclear magnetic resonance
(NMR) spectroscopy preferred. Using this technique, said blocked
interpolymers has higher molar comonomer content than a
corresponding comparable interpolymer.
[0063] Preferably, for interpolymers of ethylene and 1-octene, the
block interpolymer has a comonomer content of the TREF fraction
eluting between 40 and 130.degree. C. greater than or equal to the
quantity (-0.2013) T+20.07, more preferably greater than or equal
to the quantity (-0.2013) T+21.07, where T is the numerical value
of the peak elution temperature of the TREF fraction being
compared, measured in .degree. C.
[0064] FIG. 4 graphically depicts an embodiment of the block
interpolymers of ethylene and 1-octene where a plot of the
comonomer content versus TREF elution temperature for several
comparable ethylene/1-octene interpolymers (random copolymers) are
fit to a line representing (-0.2013) T+20.07 (solid line). The line
for the equation (-0.2013) T+21.07 is depicted by a dotted line.
Also depicted are the comonomer contents for fractions of several
block ethylene/1-octene interpolymers of the invention (multi-block
copolymers). All of the block interpolymer fractions have
significantly higher 1-octene content than either line at
equivalent elution temperatures. This result is characteristic of
the inventive interpolymer and is believed to be due to the
presence of differentiated blocks within the polymer chains, having
both crystalline and amorphous nature.
[0065] FIG. 5 graphically displays the TREF curve and comonomer
contents of polymer fractions for Example 5 and comparative F
discussed below. The peak eluting from 40 to 130.degree. C.,
preferably from 60.degree. C. to 95.degree. C. for both polymers is
fractionated into three parts, each part eluting over a temperature
range of less than 10.degree. C. Actual data for Example 5 is
represented by triangles. The skilled artisan can appreciate that
an appropriate calibration curve may be constructed for
interpolymers containing different comonomers and a line used as a
comparison fitted to the TREF values obtained from comparative
interpolymers of the same monomers, preferably random copolymers
made using a metallocene or other homogeneous catalyst composition.
Inventive interpolymers are characterized by a molar comonomer
content greater than the value determined from the calibration
curve at the same TREE elution temperature, preferably at least 5
percent greater, more preferably at least 10 percent greater.
[0066] In addition to the above aspects and properties described
herein, the inventive polymers can be characterized by one or more
additional characteristics. In one aspect, the inventive polymer is
an olefin interpolymer, preferably comprising ethylene and one or
more copolymerizable comonomers in polymerized form, characterized
by multiple blocks or segments of two or more polymerized monomer
units differing in chemical or physical properties (blocked
interpolymer), most preferably a multi-block copolymer, said block
interpolymer having a molecular fraction which elutes between
40.degree. C. and 130.degree. C., when fractionated using TREF
increments, characterized in that said fraction has a molar
comonomer content higher, preferably at least 5 percent higher,
more preferably at least 10, 15, 20 or 25 percent higher, than that
of a comparable random ethylene interpolymer fraction eluting
between the same temperatures, wherein said comparable random
ethylene interpolymer comprises the same comonomer(s), preferably
it is the same comonomer(s), and a melt index, density, and molar
comonomer content (based on the whole polymer) within 10 percent of
that of the blocked interpolymer. Preferably, the Mw/Mn of the
comparable interpolymer is also within 10 percent of that of the
blocked interpolymer and/or the comparable interpolymer has a total
comonomer content within 10 weight percent of that of the blocked
interpolymer.
[0067] Preferably, the above interpolymers are interpolymers of
ethylene and at least one .alpha.-olefin, especially those
interpolymers having a whole polymer density from about 0.855 to
about 0.935 g/cm.sup.3 and more especially for polymers having more
than about 1 mole percent comonomer, the blocked interpolymer has a
comonomer content of the TREF fraction eluting between 40 and
113.degree. C. greater than or equal to the quantity (-0.1356)
T+13.89 more preferably greater than or equal to the quantity
(-0.1356) T+14.93, and most preferably greater than or equal to the
quantity (-0.2013) T+21.07, where T is the numerical value of the
peak ATREF elution temperature of the TREF fraction being compared,
measured in .degree. C.
[0068] Preferably, for the above interpolymers of ethylene and at
least one alpha-olefin especially those interpolymers having a
whole polymer density from about 0.855 to about 0.935 g/cm.sup.3,
and more especially for polymers having more than about 1 mole
percent comonomer, the blocked interpolymer has a comonomer content
of the TREF fraction eluting between 40 and 130.degree. C. greater
than or equal to the quantity (-0.2013) T+20.07, more preferably
greater than or equal to the quantity (-0.2013) T+21.07, where T is
the numerical value of the peak elution temperature of the TREF
fraction being compared, measured in .degree. C.
[0069] In still another aspect, the inventive polymer is an olefin
interpolymer, preferably comprising ethylene and one or more
copolymerizable comonomers in polymerized form, characterized by
multiple blocks or segments of two or more polymerized monomer
units differing in chemical or physical properties (blocked
interpolymer), most preferably a multi-block copolymer, said block
interpolymer having a molecular fraction which elutes between
40.degree. C. and 130.degree. C., when fractionated using TREF
increments, characterized in that every fraction having a comonomer
content of at least about 6 mole percent, has a melting point
greater than about 100.degree. C. For those fractions having a
comonomer content from about 3 mole percent to about 6 mole
percent, every fraction has a DSC melting point of about
110.degree. C. or higher. More preferably, said polymer fractions,
having at least 1 mole percent comonomer, has a DSC melting point
that corresponds to the equation:
T.sub.m.gtoreq.(-5.5926)(mole percent comonomer in the
fraction)+135.90.
[0070] In yet another aspect, the inventive polymer is an olefin
interpolymer, preferably comprising ethylene and one or more
copolymerizable comonomers in polymerized form, characterized by
multiple blocks or segments of two or more polymerized monomer
units differing in chemical or physical properties (blocked
interpolymer), most preferably a multi-block copolymer, said block
interpolymer having a molecular fraction which elutes between
40.degree. C. and 130.degree. C., when fractionated using TREF
increments, characterized in that every fraction that has an ATREF
elution temperature greater than or equal to about 76.degree. C.,
has a melt enthalpy (heat of fusion) as measured by DSC,
corresponding to the equation:
Heat of fusion (J/gm).ltoreq.(3.1718)(ATREF elution temperature in
Celsius)-136.58,
[0071] The inventive block interpolymers have a molecular fraction
which elutes between 40.degree. C. and 130.degree. C., when
fractionated using TREF increments, characterized in that every
fraction that has an ATREF elution temperature between 40.degree.
C. and less than about 76.degree. C., has a melt enthalpy (heat of
fusion) as measured by DSC, corresponding to the equation:
Heat of fusion (J/gm).ltoreq.(1.1312)(ATREF elution temperature in
(Celsius)+22.97.
ATREF Peak Comonomer Composition Measurement by Infra-Red
Detector
[0072] The comonomer composition of the TREF peak can be measured
using an IR4 infra-red detector available from Polymer Char,
Valencia, Spain (http://www.polymerchar.com/).
[0073] The "composition mode" of the detector is equipped with a
measurement sensor (CH.sub.2) and composition sensor (CH.sub.3)
that are fixed narrow band infra-red filters in the region of
2800-3000 cm.sup.-1. The measurement sensor detects the methylene
(CH.sub.2) carbons on the polymer (which directly relates to the
polymer concentration in solution) while the composition sensor
detects the methyl (CH.sub.3) groups of the polymer. The
mathematical ratio of the composition signal (CH.sub.3) divided by
the measurement signal (CH.sub.2) is sensitive to the comonomer
content of the measured polymer in solution and its response is
calibrated with known ethylene alpha-olefin copolymer
standards.
[0074] The detector when used with an ATREF instrument provides
both a concentration (CH.sub.2) and composition (CH.sub.3) signal
response of the eluted polymer during the TREF process. A polymer
specific calibration can be created by measuring the area ratio of
the CH.sub.3 to CH.sub.2 for polymers with known comonomer content
(preferably measured by NMR). The comonomer content of an ATREF
peak of a polymer can be estimated by applying a the reference
calibration of the ratio of the areas for the individual CH.sub.3
and CH.sub.2 response (i.e. area ratio CH.sub.3/CH.sub.2 versus
comonomer content).
[0075] The area of the peaks can be calculated using a full
width/half maximum (FWHM calculation after applying the appropriate
baselines to integrate the individual signal responses from the
TREF chromatogram. The full width/half maximum calculation is based
on the ratio of methyl to methylene response area
[CH.sub.3CH.sub.2] from the ATREF infra-red detector, wherein the
tallest (highest) peak is identified from the base line, and then
the FWHM area is determined. For a distribution measured using an
ATREF peak, the FWHM area is defined as the area under the curve
between T1 and T2, where T1 and T2 are points determined, to the
left and right of the ATREF peak, by dividing the peak height by
two, and then drawing a line horizontal to the base line, that
intersects the left and right portions of the ATREF curve.
[0076] The application of infra-red spectroscopy to measure the
comonomer content of polymers in this ATREF-infra-red method is, in
principle, similar to that of GPC/FTIR systems as described in the
following references: Markovich, Ronald P.; Hazlitt, Lonnie G.;
Smith, Linley; "Development of gel-permeation
chromatography-Fourier transform infrared spectroscopy for
characterization of ethylene-based polyolefin copolymers".
Polymeric Materials Science and Engineering (1991), 65, 98-100.;
and Deslauriers, P. J.; Rohlfing, D. C.; Shieh, E. T.; "Quantifying
short chain branching microstructures in ethylene-1-olefin
copolymers using size exclusion chromatography and Fourier
transform infrared spectroscopy (SEC-FTIR)", Polymer (2002), 43,
59-170, both of which are incorporated by reference herein in their
entirety.
[0077] In other embodiments, the inventive ethylene/.alpha.-olefin
interpolymer is characterized by an average block index, ABI, which
is greater than zero and up to about 1.0 and a molecular weight
distribution, M.sub.w/M.sub.n, greater than about 1.3. The average
block index, ABI, is the weight average of the block index ("BI")
for each of the polymer fractions obtained in preparative TREF from
20.degree. C. and 110.degree. C. with an increment of 5.degree.
C.;
ABI=.SIGMA.(w.sub.iBI.sub.i)
where BI.sub.i is the block index for the ith fraction of the
inventive ethylene/.alpha.-olefin interpolymer obtained in
preparative TREF, and w.sub.i is the weight percentage of the ith
fraction.
[0078] For each polymer fraction, BI is defined by one of the two
following equations (both of which give the same BI value);
BI = 1 / T X - 1 / T XO 1 / T A - 1 / T AB or BI = - LnP X - LnP XO
LnP A - LnP AB ##EQU00001##
where T.sub.X is the preparative ATREF elution temperature for the
ith fraction (preferably expressed in Kelvin), P.sub.X is the
ethylene mole fraction for the ith fraction, which can be measured
by NMR or IR as described above. P.sub.AB is the ethylene mole
fraction of the whole ethylene/.alpha.-olefin interpolymer (before
fractionation), which also can be measured by NMR or IR. T.sub.A
and P.sub.A are the ATREF elution temperature and the ethylene mole
fraction for pure "hard segments" (which refer to the crystalline
segments of the interpolymer). As a first order approximation the
T.sub.A and P.sub.A values are set to those for high density
polyethylene homopolymer, if the actual values for the "hard
segments" are not available. For calculations performed herein,
T.sub.A is 372.degree. K, P.sub.A is 1.
[0079] T.sub.AB is the ATREF temperature for a random copolymer of
the same composition and having an ethylene mole fraction of
P.sub.AB. T.sub.AB can be calculated from the following
equation:
Ln P.sub.AB=.alpha./T.sub.AB+.beta.
where .alpha. and .beta. are two constants which can be determined
by calibration using a number of known random ethylene copolymers.
It should be noted that .alpha. and .beta. may vary from instrument
to instrument. Moreover, one would need to create their own
calibration curve with the polymer composition of interest and also
in a similar molecular weight range as the fractions. There is a
slight molecular weight effect. If the calibration curve is
obtained from similar molecular weight ranges, such effect would be
essentially negligible. In some embodiments, random ethylene
copolymers satisfy the following relationship:
Ln .beta.=-237.83/T.sub.ATREF+0.639
T.sub.XO is the ATREF temperature for a random copolymer of the
same composition and having an ethylene mole fraction of P.sub.X.
T.sub.XO can be calculated from LnP.sub.X=.alpha./T.sub.XO+.beta..
Conversely, P.sub.XO is the ethylene mole fraction for a random
copolymer of the same composition and having an ATREF temperature
of T.sub.X, which can be calculated from Ln
P.sub.XO=.alpha.T.sub.X+.beta..
[0080] Once the block index (BI) for each preparative TREF fraction
is obtained, the weight average block index, ABI, for the whole
polymer can be calculated. In some embodiments, ABI is greater than
zero but less than about 0.3 or from about 0.1 to about 0.3. In
other embodiments. ABI is greater than about 0.3 and up to about
1.0. Preferably, ABI should be in the range of from about 0.4 to
about 0.7, from about 0.5 to about 0.7, or from about 0.6 to about
0.9. In some embodiments, ABI is in the range of from about 0.3 to
about 0.9, from about 0.3 to about 0.8, or from about 0.3 to about
0.7, from about 0.3 to about 0.6, from about 0.3 to about 0.5, or
from about 0.3 to about 0.4. In other embodiments, ABI is in the
range of from about 0.4 to about 1.0, from about 0.5 to about 1.0,
or from about 0.6 to about 1.0, from about 0.7 to about 1.0, from
about 0.8 to about 1.0, or from about 0.9 to about 1.0.
[0081] Another characteristic of the inventive
ethylene/.alpha.-olefin interpolymer is that the inventive
ethylene/.alpha.-olefin interpolymer comprises at least one polymer
fraction which can be obtained by preparative TREF, wherein the
fraction has a block index greater than about 0.1 and up to about
1.0 and a molecular weight distribution, M.sub.w/M.sub.n, greater
than about 1.3. In some embodiments, the polymer fraction has a
block index greater than about 0.6 and up to about 1.0, greater
than about 0.7 and up to about 1.0, greater than about 0.8 and up
to about 1.0, or greater than about 0.9 and up to about 1.0. In
other embodiments, the polymer fraction has a block index greater
than about 0.1 and up to about 1.0, greater than about 0.2 and up
to about 1.0, greater than about 0.3 and up to about 1.0, greater
than about 0.4 and up to about 1.0, or greater than about 0.4 and
up to about 1.0. In still other embodiments, the polymer fraction
has a block index greater than about 0.1 and up to about 0.5,
greater than about 0.2 and up to about 0.5, greater than about 0.3
and up to about 0.5, or greater than about 0.4 and up to about 0.5.
In yet other embodiments, the polymer fraction has a block index
greater than about 0.2 and up to about 0.9, greater than about 0.3
and up to about 0.8, greater than about 0.4 and up to about 0.7, or
greater than about 0.5 and up to about 0.6.
[0082] For copolymers of ethylene and an .alpha.-olefin, the
inventive polymers preferably possess (1) a PDI of at least 1.3,
more preferably at least 1.5, at least 1.7, or at least 2.0, and
most preferably at least 2.6, up to a maximum value of 5.0, more
preferably up to a maximum of 3.5, and especially up to a maximum
of 2.7; (2) a heat of fusion of 80 J/g or less; (3) an ethylene
content of at least 50 weight percent; (4) a glass transition
temperature, T.sub.g, of less than -25.degree. C., more preferably
less than -30.degree. C., and or (5) one and only one T.sub.m.
[0083] Further, the inventive polymers can have, alone or in
combination with any other properties disclosed herein, a storage
modulus, G', such that log (G') is greater than or equal to 400
kPa, preferably greater than or equal to 1.0 MPa, at a temperature
of 100.degree. C. Moreover, the inventive polymers possess a
relatively flat storage modulus as a function of temperature in the
range from 0 to 100.degree. C. (illustrated in FIG. 6) that is
characteristic of block copolymers, and heretofore unknown for an
olefin copolymer, especially a copolymer of ethylene and one or
more C.sub.3-8 aliphatic .alpha.-olefins. (By the term "relatively
flat" in this context is meant that log G' (in Pascals) decreases
by less than one order of magnitude between 50 and 100.degree. C.,
preferably between 0 and 100.degree. C.).
[0084] The inventive interpolymers may be further characterized by
a thermomechanical analysis penetration depth of 1 mm at a
temperature of at least 90.degree. C. as well as a flexural modulus
of from 3 kpsi (20 MPa) to 13 kpsi (90 MPa). Alternatively, the
inventive interpolymers can have a thermomechanical analysis
penetration depth of 1 mm at a temperature of at least 104.degree.
C. as well as a flexural modulus of at least 3 kpsi (20 MPa). They
may be characterized as having an abrasion resistance (or volume
loss) of less than 90 mm.sup.3. FIG. 7 shows the TMA (1 mm) versus
flex modulus for the inventive polymers, as compared to other known
polymers. The inventive polymers have significantly better
flexibility-heat resistance balance than the other polymers.
[0085] Additionally, the ethylene/.alpha.-olefin interpolymers can
have a melt index, I.sub.2, from 0.01 to 2000 g/10 minutes
preferably from 0.01 to 1000 g/10 minutes, more preferably from
0.01 to 500 g/10 minutes, and especially from 0.01 to 100 g/10
minutes. In certain embodiments, the ethylene/.alpha.-olefin
interpolymers have a melt index, I.sub.2, from 0.01 to 10 g/10
minutes, from 0.5 to 50 g/10 minutes, from 1 to 30 g/10 minutes,
from 1 to 6 g/10 minutes or from 0.3 to 10 g/10 minutes. In certain
embodiments, the melt index for the ethylene/.alpha.-olefin
polymers is 1 g/10 minutes, 3 g/10 minutes or 5 g/10 minutes.
[0086] The polymers can have molecular weights, M.sub.w, from 1,000
g/mole to 5,000,000 g/mole, preferably from 1000 g/mole to
1,000,000, more preferably from 10,000 g/mole to 5100,000 g/mole,
and especially from 10,000 g/mole to 300,000 g/mole. The density of
the inventive polymers can be from 0.80 to 0.99 g/cm.sup.3 and
preferably for ethylene containing polymers from 0.85 g/cm.sup.3 to
0.970 cm.sup.3. In certain embodiments, the density of the
ethylene/.alpha.-olefin polymers ranges from 0.860 to 0.925
g/cm.sup.3 or 0.867 to 0.910 g/cm.sup.3.
[0087] The process of making the polymers has been disclosed in the
following patent applications: U.S. Provisional Application No.
60/553,906, filed Mar. 17, 2004; U.S. Provisional Application No.
60/662,937, filed Mar. 17, 2005: U.S. Provisional Application No.
60/662,939, filed Mar. 17, 2005; U.S. Provisional Application No.
60/566,2938, filed Mar. 17, 2005; PCT Application No.
PCT/US2005/008916, filed Mar. 17, 2005; PCT Application No.
PCT/US2005/008915, filed Mar. 17, 2005; and PCT Application No.
PCT/US2005/008917, filed Mar. 17, 2005, all of which are
incorporated by reference herein in their entirety. For example,
one such method comprises contacting ethylene and optionally one or
more addition polymerizable monomers other than ethylene under
addition polymerization conditions with a catalyst composition
comprising:
[0088] the admixture or reaction product resulting from
combining:
[0089] (A) a first olefin polymerization catalyst having a high
comonomer incorporation index,
[0090] (B) a second olefin polymerization catalyst having a
comonomer incorporation index less than 90 percent, preferably less
than 50 percent, most preferably less than 5 percent of the
comonomer incorporation index of catalyst (A), and
[0091] (C) a chain shuttling agent.
[0092] Representative catalysts and chain shuttling agent are as
follows.
[0093] Catalyst (A1) is
[N-(2,6-di(1-methylethyl)phenyl)amido)(2-isopropylphenyl)(.alpha.-naphtha-
len-2-diyl(6-pyridin-2-diyl)methane)]hafnium dimethyl, prepared
according to the teachings of WO 03740195, 2003US0204017. U.S. Ser.
No. 10/429,024 fled May 2, 2003, and WO 04/24740.
##STR00001##
[0094] Catalyst (A2) is
[N-(2,6-di(1-methylethyl)phenyl)amido)(2-methylphenyl)(1,2-phenylene-(6-p-
yridin-2-diyl)methane)]hafnium dimethyl, prepared according to the
teachings of WO 03/40195, 2003US0204017, U.S. Ser. No. 10/429,024,
filed May 2, 2003, and WO 04/24740.
##STR00002##
[0095] Catalyst (A3) is
bis[N,N'''-(2,4,6-tri(methylphenyl)amido)ethylenediamine]hafnium
dibenzyl.
##STR00003##
[0096] Catalyst (A4) is
bis((2-oxoyl-3-(dibenzo-1H-pyrrole-1-yl)-5-(methyl)phenyl)-2-phenoxymethy-
l)cyclohexane-1,2-diyl zirconium (IV) dibenzyl, prepared
substantially according to the teachings of US-A-2004/0010103.
##STR00004##
[0097] Catalyst (B1) is
1,2-bis-(3,5-di-t-butylphenylene)(1-(N-(1-methylethyl)immino)methyl)
(2-oxoyl) zirconium dibenzyl
##STR00005##
[0098] Catalyst (B2) is
1,2-bis-(3,5-di-t-butylphenylene)(1-(N-(2-methylcyclohexyl)-immino)methyl-
)(2-oxoyl) zirconium dibenzyl
##STR00006##
[0099] Catalyst (C1) is
(t-butylamido)dimethyl(3-N-pyrrolyl-1,2,3,3a,7a-.eta.-inden-1-yl)silaneti-
tanium dimethyl prepared substantially according to the techniques
of U.S. Pat. No. 6,268,444:
##STR00007##
[0100] Catalyst (C2) is
(t-butylamido)di(4-methylphenyl)(2-methyl-1,2,3,3a,7a-.eta.-inden-1-yl)si-
lanetitanium dimethyl prepared substantially according to the
teachings of US-A-2003/004286:
##STR00008##
[0101] Catalyst (C3) is
(t-butylamido)di(4-methylphenyl)(2-methyl-1,2,3,3a,8a-.eta.-s-indacen-1-y-
l)silanetitanium dimethyl prepared substantially according to the
teachings of US-A-2003/004286:
##STR00009##
[0102] Catalyst (D1) is bis(dimethyldisiloxane)
(indene-1-yl)zirconium dichloride available from Sigma-Aldrich:
##STR00010##
[0103] Shuttling Agents The shuttling agents employed include
diethylzinc, di-(i-butyl)zinc, di(n-hexyl)zinc, triethylaluminum,
trioctylaluminum, triethylgallium, i-butylaluminum
bis(dimethyl(t-butyl)siloxane), i-butylaluminum
bis(di(trimethylsilyl)amide), n-octylaluminum
di(pyridine-2-methoxide), bis(n-octadecyl)i-butylaluminum,
i-butylaluminum bis(di(n-pentyl)amide), n-octylaluminum
bis(2,6-di-t-butylphenoxide, n-octylaluminum
di(ethyl(1-naphthyl)amide), ethylaluminum
bis(t-butyldimethylsiloxide) ethylaluminum
di(bis(trimethylsilyl)amide) ethylaluminum
bis(2,3,6,7-dibenzo-1-azacycloheptaneamide), n-octylaluminum
bis(2,3,6,7-dibenzo-1-azacycloheptaneamide), n-octylaluminum
bis(dimethyl(t-butyl)siloxide, ethylzinc (2,6-diphenylphenoxide),
and ethylzinc (t-butoxide).
[0104] Preferably, the foregoing process takes the form of a
continuous solution process for forming block copolymers,
especially multi-block copolymers, preferably linear multi-block
copolymers of two or more monomers, more especially ethylene and a
C.sub.3-20 olefin or cycloolefin, and most especially ethylene and
a C.sub.4-20 .alpha.-olefin, using multiple catalysts that are
incapable of interconversion. That is, the catalysts are chemically
distinct. Under continuous solution polymerization conditions, the
process is ideally suited for polymerization of mixtures of
monomers at high monomer conversions. Under these polymerization
conditions, shuttling from the chain shuttling agent to the
catalyst becomes advantaged compared to chain growth, and
multi-block copolymers, especially linear multi-block copolymers
are formed in high efficiency.
[0105] The inventive interpolymers may be differentiated from
conventional, random copolymers, physical blends of polymers, and
block copolymers prepared via sequential monomer addition,
fluxional catalysts, anionic or cationic living polymerization
techniques. In particular, compared to a random copolymer of the
same monomers and monomer content at equivalent crystallinity or
modulus, the inventive interpolymers have better (higher) heat
resistance as measured by melting point, higher TMA penetration
temperature, higher high-temperature tensile strength, and/or
higher high-temperature torsion storage modulus as determined by
dynamic mechanical analysis. Compared to a random copolymer
containing the same monomers and monomer content, the inventive
interpolymers have lower compression set, particularly at elevated
temperatures, lower stress relaxation, higher creep resistance,
higher tear strength, higher blocking resistance, faster setup due
to higher crystallization (solidification) temperature, higher
recovery (particularly at elevated temperatures), better abrasion
resistance, higher retractive force, and better oil and filler
acceptance.
[0106] The inventive interpolymers also exhibit a unique
crystallization and branching distribution relationship. That is,
the inventive interpolymers have a relatively large difference
between the tallest peak temperature measured using CRYSTAF and DSC
as a function of heat of fusion, especially as compared to random
copolymers containing the same monomers and monomer level or
physical blends of polymers, such as a blend of a high density
polymer and a lower density copolymer, at equivalent overall
density. It is believed that this unique feature of the inventive
interpolymers is due to the unique distribution of the comonomer in
blocks within the polymer backbone. In particular, the inventive
interpolymers may comprise alternating blocks of differing
comonomer content (including homopolymer blocks). The inventive
interpolymers may also comprise a distribution in number and/, or
lock size of polymer blocks of differing density or comonomer
content, which is a Schultz-Flory type of distribution. In addition
the inventive interpolymers also have a unique peak melting point
and crystallization temperature profile that is substantially
independent of polymer density, modulus, and morphology. In a
preferred embodiment, the microcrystalline order of the polymers
demonstrates characteristic spherulites and lamellae that are
distinguishable from random or block copolymers, even at PDI values
that are less than 1.7, or even less than 1.5, down to less than
1.3.
[0107] Moreover, the inventive interpolymers may be prepared using
techniques to influence the degree or level of blockiness. That is
the amount of comonomer and length of each polymer block or segment
can be altered by controlling the ratio and type of catalysts and
shuttling agent as well as the temperature of the polymerization,
and other polymerization variables. A surprising benefit of this
phenomenon is the discovery that as the degree of blockiness is
increased, the optical properties, tear strength, and high
temperature recovery properties of the resulting polymer are
improved. In particular, haze decreases while clarity, tear
strength, and high temperature recovery properties increase as the
average number of blocks in the polymer increases. By selecting
shuttling agents and catalyst combinations having the desired chain
transferring ability (high rates of shuttling with low levels of
chain termination) other forms of polymer termination are
effectively suppressed. Accordingly, little if any .beta.-hydride
elimination is observed in the polymerization of
ethylene/.alpha.-olefin comonomer mixtures according to embodiments
of the invention, and the resulting crystalline blocks are highly,
or substantially completely, linear, possessing little or no long
chain branching.
[0108] Polymers with highly crystalline chain ends can be
selectively prepared in accordance with embodiments of the
invention. In elastomer applications, reducing the relative
quantity of polymer that terminates with an amorphous block reduces
the intermolecular dilutive effect on crystalline regions. This
result can be obtained by choosing chain shuttling agents and
catalysts having an appropriate response to hydrogen or other chain
terminating agents.
[0109] Specifically, if the catalyst which produces highly
crystalline polymer is more susceptible to chain termination (such
as by use of hydrogen) than the catalyst responsible for producing
the less crystalline polymer segment (such as through higher
comonomer incorporation, regio-error, or atactic polymer
formation), then the highly crystalline polymer segments will
preferentially populate the terminal portions of the polymer. Not
only are the resulting terminated groups crystalline, but upon
termination, the highly crystalline polymer forming catalyst site
is once again available for reinitiation of polymer formation. The
initially formed polymer is therefore another highly crystalline
polymer segment. Accordingly, both ends of the resulting
multi-block copolymer are preferentially highly crystalline.
[0110] The ethylene .alpha.-olefin interpolymers used in the
embodiments of the invention are preferably interpolymers of
ethylene with at least one C.sub.3-C.sub.20 t-olefin. Copolymers of
ethylene and a C.sub.3-C.sub.20 .alpha.-olefin are especially
preferred. The interpolymers may further comprise C.sub.4-C.sub.18
diolefin and/or alkenylbenzene. Suitable unsaturated comonomers
useful for polymerizing with ethylene include, for example,
ethylenically unsaturated monomers, conjugated or nonconjugated
dienes, polyenes, alkenylbenzenes, etc. Examples of such comonomers
include C.sub.3-C.sub.20 .alpha.-olefins such as propylene,
isobutylene, 1-butene, 1-hexene, 1-pentene, 4-methyl-1-pentene,
1-heptene, 1-octene, 1-nonene, 1-decene, and the like. 1-Butene and
1-octene are especially preferred. Other suitable monomers include
styrene, halo- or alkyl-substituted styrenes,
vinylbenzocyclobutane, 1,4-hexadiene, 1,7-octadiene, and
naphthenics (e.g., cyclopentene, cyclohexene and cyclooctene).
[0111] While ethylene/.alpha.-olefin interpolymers are preferred
polymers, other ethylene/olefin polymers may also be used. Olefins
as used herein refer to a family of unsaturated hydrocarbon-based
compounds with at least one carbon-carbon double bond. Depending on
the selection of catalysts, any olefin may be used in embodiments
of the invention. Preferably, suitable olefins are C.sub.3-C.sub.20
aliphatic and aromatic compounds containing vinylic unsaturation,
as well as cyclic compounds, such as cyclobutene, cyclopentene,
dicyclopentadiene, and norbornene, including but not limited to
norbornene substituted in the 5 and 6 position with
C.sub.1-C.sub.20 hydrocarbyl or cyclohydrocarbyl groups. Also
included are mixtures of such olefins as well as mixtures of such
olefins with C.sub.4-C.sub.40 diolefin compounds.
[0112] Examples of olefin monomers include, but are not limited to
propylene, isobutylene, 1-butene, 1-pentene, 1-hexene, 1-heptene,
1-octene, 1-nonene, 1-decene, and 1-dodecene, 1-tetradecene,
1-hexadecene, 1-octadecene, 1-eicosene, 3-methyl-1-butene,
3-methyl-1-pentene, 4-methyl-1-pentene, 4,6-dimethyl-1-heptene,
4-vinylcyclohexene, vinylcyclohexane, norbornadiene, ethylidene
norbornene, cyclopentene, cyclohexene, dicyclopentadiene,
cyclooctene, C.sub.4-C.sub.40 dienes, including but not limited to
1,3-butadiene, 1,3-pentadiene, 1,4-hexadiene, 1,5-hexadiene,
1,7-octadiene, 1,9-decadiene, other C.sub.4-C.sub.40
.alpha.-olefins, and the like. In certain embodiments, the
.alpha.-olefin is propylene, 1-butene, 1-pentene, 1-hexene,
1-octene or a combination thereof. Although any hydrocarbon
containing a vinyl group potentially may be used in embodiments of
the invention, practical issues such as monomer availability, cost,
and the ability to conveniently remove unreacted monomer from the
resulting polymer may become more problematic as the molecular
weight of the monomer becomes too high.
[0113] The polymerization processes described herein are well
suited for the production of olefin polymers comprising
monovinylidene aromatic monomers including styrene, o-methyl
styrene, p-methyl styrene, t-butylstyrene, and the like. In
particular, interpolymers comprising ethylene and styrene can be
prepared by following the teachings herein. Optionally, copolymers
comprising ethylene, styrene and a C.sub.3-C.sub.20 alpha olefin,
optionally comprising a C.sub.4-C.sub.20 diene, having improved
properties can be prepared.
[0114] Suitable non-conjugated diene monomers can be a straight
chain, branched chain or cyclic hydrocarbon diene having from 6 to
15 carbon atoms. Examples of suitable non-conjugated dienes
include, but are not limited to, straight chain acyclic dienes,
such as 1,4-hexadiene, 1,6-octadiene, 1,7-octadiene, 1,9-decadiene,
branched chain acyclic dienes, such as 5-methyl-1,4-hexadiene;
3,7-dimethyl-1,6-octadiene; 3,7-dimethyl-1,7-octadiene and mixed
isomers of dihydromyricene and dihydroocinene, single ring
alicyclic dienes, such as 1,3-cyclopentadiene; 1,4-cyclohexadiene;
1,5-cyclooctadiene and 1,5-cyclododecadiene, and multi-ring
alicyclic fused and bridged ring dienes, such as tetrahydroindene,
methyl tetrahydroindene, dicyelopentadiene,
bicyclo-(2,2,1)-hepta-2,5-diene; alkenyl, alkylidene, cycloalkenyl
and cycloalkylidene norbornenes, such as 5-methylene-2-norbornene
(MNB); 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene,
5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene,
5-vinyl-2-norbornene, and norbornadiene. Of the dienes typically
used to prepare EPDMs the particularly preferred dienes are
1,4-hexadiene (HD), 5-ethylidene-2-norbornene (ENB),
5-vinylidene-2-norbornene (VNB), 5-methylene-2-norbornene (MNB),
and dicyclopentadiene (DCPD). The especially preferred dienes are
5-ethylidene-2-norbornene (ENB) and 1,4-hexadiene (HD).
[0115] One class of desirable polymers that can be made in
accordance with embodiments of the invention are elastomeric
interpolymers of ethylene, a C.sub.3-C.sub.20 .alpha.-olefin,
especially propylene, and optionally one or more diene monomers.
Preferred .alpha.-olefins for use in this embodiment of the present
invention are designated by the formula CH.sub.2CHR*, where R* is a
linear or branched alkyl group of from 1 to 12 carbon atoms
Examples of suitable .alpha.-olefins include, but are not limited
to, propylene, isobutylene, 1-butene, 1-pentene, 1-hexene,
4-methyl-1-pentene, and 1-octene. A particularly preferred
.alpha.-olefin is propylene. The propylene based polymers are
generally referred to in the art as EP or EPDM polymers. Suitable
dienes for use in preparing such polymers, especially multi-block
EPDM type polymers include conjugated or non-conjugated, straight
or branched chain-, cyclic- or polycyclic-dienes comprising from 4
to 20 carbons. Preferred dienes include 1,4-pentadiene,
1,4-hexadiene, 5-ethylidene-2-norbornene, dicyclopentadiene,
cyclohexadiene, and 5-butylidene-2-norbornene. A particularly
preferred diene is 5-ethylidene-2-norbornene.
[0116] Because the diene containing polymers comprise alternating
segments or blocks containing greater or lesser quantities of the
diene (including none) and .alpha.-olefin (including none), the
total quantity of diene and .alpha.-olefin may be reduced without
loss of subsequent polymer properties. That is, because the diene
and .alpha.-olefin monomers are preferentially incorporated into
one type of block of the polymer rather than uniformly or randomly
throughout the polymer, they are more efficiently utilized and
subsequently the crosslink density of the polymer can be better
controlled. Such crosslinkable elastomers and the cured products
have advantaged properties, including higher tensile strength and
better elastic recovery.
[0117] In some embodiments, the inventive interpolymers made with
two catalysts incorporating differing quantities of comonomer have
a weight ratio of blocks formed thereby from 95:5 to 5:95. The
elastomeric polymers desirably have an ethylene content of from 20
to 90 percent, a diene content of from 0.1 to 10 percent, and an
.alpha.-olefin content of from 10 to 80 percent, based on the total
weight of the polymer. Further preferably, the multi-block
elastomeric polymers have an ethylene content of from 60 to 90
percent, a diene content of from 0.1 to 10 percent, and an
.alpha.-olefin content of from 10 to 40 percent, based on the total
weight of the polymer. Preferred polymers are high molecular weight
polymers, having a weight average molecular weight (Mw) from 10,000
to about 2,500,000, preferably from 20,000 to 500,000, more
preferably from 20,000 to 350,000, and a polydispersity less than
3.5, more preferably less than 3.0, ad a Mooney viscosity (ML (1+4)
125.degree. C.) from 1 to 250. More preferably, such polymers have
an ethylene content from 65 to 75 percent, a diene content from 0
to 6 percent, and an .alpha.-olefin content from 20 to 35
percent.
[0118] The ethylene/.alpha.-olefin interpolymers can be
functionalized by incorporating at least one functional group in
its polymer structure. Exemplary functional groups may include, for
example, ethylenically unsaturated mono- and di-functional
carboxylic acids, ethylenically unsaturated mono- and di-functional
carboxylic acid anhydrides, salts thereof and esters thereof. Such
functional groups may be grafted to an ethylene/.alpha.-olefin
interpolymer, or it may be copolymerized with ethylene and an
optional additional comonomer to form an interpolymer of ethylene,
the functional comonomer and optionally other comonomer(s). Means
for grafting functional groups onto polyethylene are described for
example in U.S. Pat. Nos. 4,762,890, 4,927,888, and 4,950,541, the
disclosures of these patents are incorporated herein by reference
in their entirety. One particularly useful functional group is
malic anhydride.
[0119] The amount of the functional group present in the functional
interpolymer can vary. The functional group can typically be
present in a copolymer-type functionalized interpolymer in an
amount of at least about 1.0 weight percent, preferably at least
about 5 weight percent, and more preferably at least about 7 weight
percent. The functional group will typically be present in a
copolymer-type functionalized interpolymer in an amount less than
about 40 weight percent, preferably less than about 30 weight
percent, and more preferably less than about 25 weight percent.
Elastic Fiber
[0120] The amount of ethylene/.alpha.-olefin interpolymer in a
given fabric depends upon the desired properties, desired
applications, and other components of the fabric. In one
embodiment, the ethylene/.alpha.-olefin interpolymer comprises at
least about 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 14, 16, 18, 20, 23, 24,
26, or 28 up to 30 percent or more by weight of the fabric. The
ethylene/.alpha.-olefin interpolymer may comprise less than about
30, 28, 26, 24, 22, 20, 18, 16, 14, 12, 10, 9, 8, 7, 6, 5, 4, or 3
weight percent of the fabric. Typically, the
ethylene/.alpha.-olefin interpolymer is in the form of a fiber
having elastic properties and often may comprise from about 1 to
about 30, preferably from about 2 to about 10, weight percent of
the fabric.
[0121] A material is typically characterized as elastic (or as
having stretch) if it has a high percent elastic recovery (that is,
a low percent permanent set) after application of a biasing force.
In certain embodiments, elastic materials are characterized by a
combination of three important properties, that is, (i) a low
stress or load at strain; (ii) a low percent stress or load
relaxation, and (iii) a low percent permanent set. In other words,
there should be (i) a low stress or load requirement to stretch the
material, (ii) zero or low relaxing of the stress or unloading once
the material is stretched, and (iii) complete or high recovery to
original dimensions after the stretching, biasing or straining is
discontinued.
[0122] The fiber used in the articles provided herein typically
recovers at least about 40 percent, at least about 50 percent, at
least about 60 percent, about 70 percent or more of its stretched
length after the first pull and after the fourth to 100 percent
strain (double the length). One suitable way to do this test is
based on the one found in the International Bureau for
Standardization of Manmade Fibers, BISFA 1998, chapter 7, option A.
Under such a test, the fiber is placed between grips set 4 inches
apart, the grips are then pulled apart at a rate of about 20 inches
per minute to a distance of eight inches and then allowed to
immediately recover. The percent recovery is then measured.
[0123] In certain embodiments, the fiber provided herein further
comprises crosslinked homogeneously branched ethylene polymers,
such as those described in U.S. Pat. No. 6,437,014, and is
generically known as lastol. The amount of such homogeneously
branched ethylene polymers differs depending upon the elasticity
desired and compatibility with the specific ethylene/.alpha.-olefin
interpolymer employed.
[0124] In certain embodiments, the fiber used herein further
comprises other polymers, for example, random ethylene copolymers
such as AFFINITY.RTM. or ENGAGE.RTM., traditional polyethylenes
such as HDPE, LLDPE, ULDPE, LDPE and propylene-based polymers such
as homopolymer PP, random copolymer PP or PP-based
plastomers/elastomers or a combination thereof. The amount of such
other polymers differs depending upon the elasticity desired and
compatibility with the specific ethylene/.alpha.-olefin
interpolymer employed.
[0125] If desired an additional stretch material may be employed in
addition to the ethylene/.alpha.-olefin interpolymer. For example,
the ethylene/.alpha.-olefin interpolymer fiber may be employed in
either the warp or weft direction while the second stretch material
is employed in the remaining direction. Suitable additional stretch
materials may include elastic fibers comprised of a polymer
selected from the group consisting of polybutylene terephthalate,
spandex, poly(ethylene terephthalate), poly(trimethylene
terephthalate), or mixtures thereof. Such mixtures include
bicomponent fibers of poly(ethylene
terephthalate)/poly(trimethylene terephthalate) such as, for
example, T-400.TM. fibers. While the elasticity and properties vary
depending upon the materials and construction of the fabric, it may
be desirable to employ ethylene/.alpha.-olefin interpolymer fibers
in the warp direction and the additional stretch material in the
weft direction.
[0126] The fibers may be made into any desirable size and
cross-sectional shape depending upon the desired application. For
many applications approximately round cross-section is desirable
due to its reduced friction. However, other shapes such as a
trilobal shape, or a flat (i.e., "ribbon" like) shape can also be
employed. Denier is a textile term which is defined as the grams of
the fiber per 9000 meters of that fiber's length. Preferred sizes
include a denier from at least about 1, preferably at least about
20, preferably at least about 50, to at most about 180, preferably
at most about 150, preferably at most about 100 denier, preferably
at most about 80 denier. For example, the fiber thickness may range
from about 1 to 180 denier, from about 5 to about 160 denier from
about 10 to about 150 denier, from about 20 to about 140 denier,
from about 30 to about 120 denier, from about 40 to about 100
denier, from about 50 to about 90 denier, or from about 40 to about
70 denier.
[0127] In certain embodiments, the ethylene/.alpha.-olefin
interpolymer is in the form of a fiber having a gel content of from
about 10% to about 75% by weight. In certain embodiments, the
ethylene/.alpha.-olefin interpolymer is in the form of a fiber
having a gel content of from about 10%, 30%, 40%, 50%, 60% or about
75% by weight. In certain embodiments, the ethylene/.alpha.-olefin
interpolymer is in the form of a fiber having a gel content of at
least about 10% by weight.
[0128] The fiber is usually elastic and usually cross-linked. The
fiber comprises the reaction product of ethylene/.alpha.-olefin
interpolymer and any suitable cross-linking agent, i.e., a
cross-linked ethylene/.alpha.-olefin interpolymer. As used herein,
"cross-linking agent" is any means which cross-links one or more,
preferably a majority, of the fibers. Thus, cross-linking agents
may be chemical compounds but are not necessarily so. Cross-linking
agents as used herein also include electron-beam irradiation, beta
irradiation, gamma irradiation, corona irradiation, silanes,
peroxides, allyl compounds and UV radiation with or without
crosslinking catalyst. U.S. Pat. Nos. 6,803,014 and 6,667,351
disclose electron-beam irradiation methods that cm be used in
embodiments of the invention. In some embodiments, the percent of
cross-linked polymer is at least 10 percent, preferably at least
about 20, more preferably at least about 25 weight percent to about
at most 75, preferably at most about 50 percent, as measured by the
weight percent of gels formed.
[0129] Depending upon the application the fiber may take any
suitable form including a staple fiber or binder fiber. Typical
examples may include filaments, homofil fiber, a or bicomponent
fiber. In the case of a bicomponent fiber it may have a sheath-core
structure; a sea-island structure; a side-by-side structure; a
matrix-fibril structure; or a segmented pie structure.
Advantageously, conventional fiber forming processes may be
employed to make the aforementioned fibers. Such processes include
those described in for example, U.S. Pat. Nos. 4,340,563;
4,663,220; 4,668,566; 4,322,027; and 4,413,110).
[0130] The fibers of the present invention facilitate processing in
a number of respects. First, the inventive fibers unwind better
from a spool than conventional fibers. Ordinary fibers when in
round cross section often fail to provide satisfactory unwinding
performance due to their base polymer excessive stress relaxation.
This stress relaxation is proportional to the age of the spool and
causes filaments located at the very surface of the spool to lose
grip on the surface, becoming loose filament strands. Later, when
such a spool containing conventional fibers is placed over the
rolls of positive feeders, i.e. Memminger-IRO, and starts to rotate
to industrial speeds, i.e. 100 to 300 rotations/minute, the loose
fibers are thrown to the sides of the spool surface and ultimately
fall off the edge of the spool. This failure is known as derails
which denotes the tendency of conventional fibers to slip off the
shoulder or edge of the package which disrupts the unwinding
process and ultimately causes machine stops. The inventive fibers
exhibit derailing to a much less significant degree which allows
greater throughput.
Other Material
[0131] The other material or materials used in the wrinkle free
fabric provided herein is often selected from the group consisting
of cellulose, cotton, flax, ramie, rayon, viscose, hemp, linen,
bamboo, tencel, viscose, mohair, polyester, polyamide,
polypropylene, and animal fibers such as wool, silk, or keratin. In
addition, mixtures of the aforementioned materials may be employed.
Preferred fabrics include those wherein the other material
comprises cellulose, wool, or mixtures thereof and wherein the
fabric is knitted or woven. If the fabric is going to be subjected
to a wrinkle-resistance treatment then it is useful if the other
material is capable of withstanding such treatment.
[0132] In one embodiment, the textile articles provided herein
include cellulosic materials. In one aspect, the cellulosic
materials comprise 60 to 98 percent, 65-90 percent or 70-85 percent
by weight of the textile article. In one embodiment, the cellulosic
materials comprise greater than about 90 percent by weight of the
textile article. In certain embodiments, the fabrics comprise
cotton. One or more other materials can also be used in the textile
articles of the present invention, either one or in combination
with cellulosic materials. These other materials include natural
fibers such as wool, silk or mohair and synthetic fibers such as
polyester, polyamide or polypropylene.
[0133] In one embodiment, the elastic fiber in the articles
provided herein may be used neat, or it may first be incorporated
into a multifilament yarn. In many applications the elastic fiber
may be wrapped with a natural fiber, such as cotton.
[0134] The selection of non-elastic fibers used in the fabric
provided herein may depend on the desired fabric construction and
the process used to impart wrinkle resistance to the fabric, so as
to ensure that the fibers selected have suitable tenacity. For
example, if a lightweight cotton-containing fabric is desired and a
relatively harsh chemical treatment will be used to impart sprinkle
resistance, then it may be advantageous to use a cotton fiber with
higher initial tenacity, such as PIMA cotton so that the fibers in
the finished fabric will still have acceptable tenacity.
Properties
[0135] As provided herein, an article, e.g., fabric or garment, is
considered to be elastic or to be a "stretch", article if the
article can be stretched at least five percent in the warp and/or
weft direction, at least about 8, 9, 10, 11, 12, 13, 14, 18, 20 up
to at least about 25 percent. Some fabrics may be stretched in two
directions, i.e., the warp and weft directions. The fabric returns
to a value closer to its original dimensions after release of the
stretching force as per ASTM D3107-1980. The fabrics provided
herein often exhibit a growth to stretch ratio of less than 0.5,
preferably less than 0.4, preferably less than 0.35, preferably
less than 0.3, preferably less than 0.25, preferably less than 0.2,
preferably less than 0.15, preferably less than 0.1, preferably
less than 0.05. For example, a fabric which stretches 25 percent
and which recovers to a value 5 percent greater than original
dimension would have a ratio of 0.2. It should be understood that
the amount of stretch and recovery will be a function of the weight
of the fabric (that is, lighter weight fabrics such as voile will
generally have more stretch and less recovery) and the fabric
construction (for example herringbone fabrics are known to have
greater stretch). In some instances, the article can be stretched
at least 15 percent, and even at least 25 percent, in the warp
and/or weft direction. It is also contemplated that in certain
embodiments, the articles provided herein will have stretch in more
than one direction. It is not necessary that the articles have
stretch in more than one direction or that the articles have the
same amount of stretch in each direction to be within the scope of
this invention.
[0136] It is also advantageous that the textile articles provided
herein can be rendered wrinkle resistant. Typical wrinkle-free
treatments (also sometimes referred to as a durable press coating)
include imparting hydrogen or covalent bonds that do not
significantly degrade when the fabric is cleaned in some fashion,
typically by hand or machine washing. In this sense the bonds are
permanent and the fabric is relatively wrinkle-free during its
useful life. Typical durable press coatings often involve the
application of a chemical coating to the surface of the fabric,
i.e., textile. These coatings usually include a cross-linking agent
and catalyst such that cross-links form between the agent and a
material, e.g. cellulose, in the fibers. The crosslinks not only
provide wrinkle resistance but may also improve dimensional
stability, increase fabric smoothness and improve crease retention.
The chemical coatings which are often currently used to impart
wrinkle resistance to a textile, are relatively harsh. The
inventive stretch fabrics and garments made of same are often
capable of enduring common chemical treatment or heat (curing)
treatments used for wrinkle resistance.
[0137] Wrinkle resistance in the textile industry can be measured
according to AATCC 143-1996 (for garments) or AATCC-124-2001 (for
finished fabric) or Marks and Spencer P134. Using this testing
protocol, in certain embodiments, the articles provided herein will
have a durable press (or DP) rating of at least 3.0 after five
washes, at least 3.5 or at least about 4.0. In one embodiment, the
DP rating will remain at least 3.0 after 25 or even 50 washes.
[0138] In some applications, such as pants, it is desired that the
article maintains a crease. This desire to maintain a crease
sometimes conflicts with technical solutions used to deter
wrinkles. Nevertheless, using the fabrics of the present invention
such wrinkle-resistant, creased articles are possible. In one
embodiment, textile articles provided herein exhibit a Crease
Retention ("CR") rating of at least 3.5, as determined according to
the testing protocol set forth in AATCC 143-1996. In one
embodiment. AATCC 143-1996 3(IV) A(iii), is used for determining
CR. Accordingly, the textile articles of the present invention will
have a CR of at least about 2.5, 3.0, 3.5, 4.0, 4.5 or 5.
Methods for Preparing Exemplary Articles
[0139] Articles provided herein are not limited by the method of
making them. Thus, the articles of the present invention include
fabrics which have been, for example, woven (where the elastic
fiber can be in the warp direction, the weft direction or both) or
knitted. In one embodiment, the wrinkle free articles provided
herein can be generated by:
[0140] a) No-iron fabric treatments: The cotton (cotton content of
>80%) and ethylene .alpha.-olefin interpolymer fiber/cotton yarn
is weaved into a particular fabric weaving construction after which
the fabric is impregnated with resin blends and followed by
moisture cure. After the chemical resin treatment, this fabric is
stretchable and wrinkle free, with DP ratings above 3.5 after 5
times of washing and the Crease Retention rating >3.5 after 5
times of washing. The garment, which is made with this fabric,
forms the stretchable wrinkle free garment.
[0141] b) No-iron garment treatments: The cotton (cotton content of
>80%) and ethylene .alpha.-olefin interpolymer fiber/cotton yarn
is weaved into a particular fabric weaving construction after which
the fabric goes through the garment making process. Then the
chemical resin is applied on the garment, and the garment is cured
tinder certain temperatures and pH values. After the curing
process, the above garment is stretchable and wrinkle fee, with DP
rating >3.5 after 5 times of washing, and Crease Retention
rating >3.5 after 5 times of washing.
[0142] This invention can be applied to all kind of chemical resin
finishing on cotton and ethylene .alpha.-olefin interpolymer blend
fabrics (woven or knitted). Standard wrinkle free processes have
many ways of producing a wrinkle free garment including selecting
the order of processing steps and/or choosing different processing
temperatures, chemical resins and pH values. A combination of these
conditions can be selected to produce a similar wrinkle free fabric
or garment.
[0143] One skilled in the art may take the fabrics of the present
invention and use conventional techniques to prepare garments and
other useful textiles that exhibit desired properties such as
wrinkle-resistance or crease retention. In certain embodiments,
such processes includes one or more of the following steps: yarn
formation, yarn dyeing fabric making, fabric finishing, including
wrinkle free treatment. The sequence of steps involved in exemplary
processes is as follows:
[0144] Route 1 (yarn dyeing): Yarn formation (spinning, steaming,
winding)-yarn dyeing (dyeing, extracting, drying)-fabric making
(reconing, conditioning, weaving)-fabric finishing (singeing,
scouring, mercerizing, wrinkle free treatment (including curing),
softening, sanforizing).
[0145] Route 2 (piece dyeing): Yarn formation (spinning, streaming
(optional for standard elastic fiber), winding)-fabric making
(reconing, conditioning, weaving)-fabric finishing (singeing,
scouring, mercerizing, fabric dyeing, wrinkle free treatment,
softening, sanforizing).
[0146] Route 3 (wrinkle free garment) Yarn formation (spinning,
steaming, winding)-yarn dyeing (dyeing, extracting, drying)-fabric
making (reconing, conditioning, weaving)-fabric finishing
(singeing, scouring, mercerizing, softening, sanforizing)-garment
making-garment dipping process for wrinkle free treatment.
[0147] Route 4. (wrinkle free garment) Yarn formation (spinning,
streaming (optional for standard elastic fiber), winding)-fabric
making (reconing, conditioning, weaving)-fabric finishing
(singeing, scouring, mercerizing, fabric dyeing, softening,
sanforizing)-garment making-garment dipping process for wrinkle
free treatment.
[0148] Any method known to impart wrinkle resistance may be used
with the textile articles provided herein. Most commercial wrinkle
free treatments use formaldehyde-Based Durable Press Finishing
Agents, DMDHEU (dimethyloldihydroxyethyleneurea), modified DMDHEU,
Polycarboxylic Acids as Nonformaldehyde Durable Press Finishing
Agents since 1990s, BTCA, Modified Citric Acid or Polymers of
Maleic Acid.
[0149] Typically fabrics are prepared and then a finishing solution
containing a cross-linking agent together with a catalyst is
applied. The application of the finishing solution can be applied
to the fabric or to the finished article, as is known in the art.
In general, the crosslinking agent and curing catalyst are applied
by immersing the cellulosic material into a bath containing the
finishing solution, but other methods such as spraying, are known
and can be used to make the textile articles of the present
invention. Another method for producing wrinkle-resistant garments
involves subjecting a pressed garment in a reaction chamber
containing sulphur dioxide, formaldehyde and steam where
cross-linking of cellulose occurs in situ. Typical cross-linking
agents include formaldehyde, formaldehyde derivatives (including
addition products with urea) and carbamate esters. Other
cross-linking agents are described in WO 89/12714 (organic
polycarboxylic acids), U.S. Pat. No. 5,300,240 (phosphinicosuccinic
and/or phosphinicobisuccinic acids); U.S. Pat. No. 6,585,780
(phosphinato-substituted polycarboxylic acids) and US 2003/0111633
A1. These references are hereby incorporated by reference in their
entirety.
[0150] In one embodiment, an ethylene/.alpha.-olefin interpolymer
fiber is made and then crosslinked to about 10% to 75% gel for use
in the process for preparing an article provided herein. In one
embodiment, a core spun yarn is then prepared comprising ethylene
.alpha.-olefin interpolymer as the core and other "hard" fibers
(staple fibers) as the covering. Other hard fibers could include
pure cotton, pure silk pure linen, bamboo fiber, tencel, viscose,
and their blends, or polyester/cotton blend. In one embodiment, the
other fiber is pure cotton or pure silk.
[0151] In addition to core spinning (staple), other yarn spinning
processes can be used and include, but are not limited to Siro
spinning (staple), Single covering (staple or continuous), Double
covering (staple or continuous), or Air covering (continues
filament). In one embodiment, yarns are core spun or siro spun.
Both bistretch and one way stretch (weft stretch) are contemplated
herein.
[0152] In one embodiment, the yarn count is from Ne 100 to Ne 7
from shirting to bottom weight fabrics, respectively. In another
embodiment, the yarn count is from Ne 90 to Ne 7, Ne 80 to Ne 7 or
Ne 70 to Ne 7. In one embodiment, the range of yarn count is Ne 50
to Ne 7.
[0153] The dyeing is carried out at a temperature range from 60 to
200.degree. C. for about 1-2 hours or more. In certain embodiments,
the dyeing is carried out at a temperature of about 60, 80, 100,
120, 140, 160, 180 or 200.degree. C. The fabric can be plain,
twill, basket, satin, pinpoint oxford, canvas, broken twill, dobby,
corduroy weaved. In certain embodiments, the fabric is plain,
twill, basket, satin or pinpoint oxford weaved. In one embodiment,
the fabric is knitted.
[0154] An exemplary finished fabric has the following properties:
Tenacity: 50 lb (shirting), 75 lb. (bottom); Fabric tearing
strength: 4.5 lb. (shirting), 5.1 lb (bottom) (measured according
to ASTM D3107); Abrasion resistance >1,800 rpm (shirting),
35,000 (bottom); Water absorption time <10 second for both
shirting and bottom. Washing shrinkage <3% and Stretch level:
9-20%.
Testing Methods
[0155] In the examples that follow, the following analytical
techniques are employed:
GPC Method for Samples 1-4 and A-C
[0156] An automated liquid-handling robot equipped with a heated
needle set to 160.degree. C. is used to add enough
1,2,4-trichlorobenzene stabilized with 300 ppm lonol to each dried
polymer sample to give a final concentration of 30 mg/mL. A small
glass stir rod is placed into each tube and the samples are heated
to 160.degree. C. for 2 hours on a heated orbital-shaker rotating
at 250 rpm. The concentrated polymer solution is then diluted to 1
mg/ml using the automated liquid-handling robot and the heated
needle set to 160.degree. C.
[0157] A Symyx Rapid GPC system is used to determine the molecular
weight data for each sample. A Gilson 350 pump set at 2.0 mim/min
flow rate is used to pump helium-purged 1,2-dichlorobenzene
stabilized with 300 ppm lonol as the mobile phase through three
Pigel 10 micrometer (.mu.m) Mixed B 300 mm.times.7.5 mm columns
placed in series and heated to 160.degree. C. A Polymer Labs ELS
1000 Detector is used with the Evaporator set to 250.degree. C.,
the Nebulizer set to 165.degree. C., and the nitrogen flow rate set
to 1.8 SLM at a pressure of 60-80 psi (400-600 kPa) N.sub.2. The
polymer samples are heated to 160.degree. C. and each sample
injected into a 250 .mu.l loop using the liquid-handling robot and
a heated needle. Serial analysis of the polymer samples using two
switched loops and overlapping injections are used. The sample data
is collected and analyzed using Symyx Epoch.TM. software. Peaks are
manually integrated and the molecular weight information reported
uncorrected against a polystyrene standard calibration curve.
Standard CRYSTAF Method
[0158] Branching distributions are determined by crystallization
analysis fractionation (CRYSTAF) using a CRYSTAF 200 unit
commercially available from PolymerChar, Valencia, Spain. The
samples are dissolved in 1.2.4 trichlorobenzene at 160.degree. C.
(0.66 mg/mL) for 1 hr and stabilized at 95.degree. C. for 45
minutes. The sampling temperatures range from 95 to 30.degree. C.
at a cooling rate of 0.2.degree. C./min. An infrared detector is
used to measure the polymer solution concentrations. The cumulative
soluble concentration is measured as the polymer crystallizes while
the temperature is decreased. The analytical derivative of the
cumulative profile reflects the short chain branching distribution
of the polymer.
[0159] The CRYSTAF peak temperature and area are identified by the
peak analysis module included in the CRYSTAF Software (Version
2001.b, PolymerChar, Valencia. Spain). The CRYSTAF peak finding
routine identifies a peak temperature as a maximum in the dW, dT
curve and the area between the largest positive inflections on
either side of the identified peak in the derivative curve. To
calculate the CRYSTAF curve, the preferred processing parameters
are with a temperature limit of 70.degree. C. and with smoothing
parameters above the temperature limit of 0.1, and below the
temperature limit of 0.3.
[0160] DSC Standard Method (Excluding Samples 1-4 and A-C)
[0161] Differential Scanning Calorimetry results are determined
using a TAI model Q1000 DSC equipped with an RCS cooling accessory
and an autosampler. A nitrogen purge gas flow of 50 ml/min is used.
The sample is pressed into a thin film and melted in the press at
about 175.degree. C. and then air-cooled to room temperature
(25.degree. C.). 3-10 mg of material is then cut into a 6 mm
diameter disk, accurately weighed, placed in a light aluminum pan
(ea 50 mg), and then crimped shut. The thermal behavior of the
sample is investigated with the following temperature profile. The
sample is rapidly heated to 180.degree. C. and held isothermal for
3 minutes in order to remove any previous thermal history. The
sample is then cooled to -40.degree. C. at 10.degree. C./min
cooling rate and held at -40.degree. C. for 3 minutes. The sample
is then heated to 150.degree. C. at 10.degree. C./min. heating
rate. The cooling and second heating curves are recorded.
[0162] The DSC melting peak is measured as the maximum in heat flow
rate (W/g) with respect to the linear baseline drawn between
-30.degree. C. and end of melting. The heat of fusion is measured
as the area under the melting curve between -30.degree. C. and the
end of melting using a linear baseline.
GPC Method (Excluding Samples 1-4 and A-C)
[0163] The gel permeation chromatographic system consists of either
a Polymer Laboratories Model PL-210 or a Polymer Laboratories Model
PL-220 instrument. The column and carousel compartments are
operated at 140.degree. C. Three Polymer Laboratories 10-micron
Mixed-B columns are used. The solvent is 1,2,4 trichlorobenzene.
The samples are prepared at a concentration of 0.1 grams of polymer
in 50 milliliters of solvent containing 200 ppm of butylated
hydroxytoluene (BHT), Samples are prepared by agitating lightly for
2 hours at 160.degree. C. The injection volume used is 100
microliters and the flow rate is 1.0 ml/minute.
[0164] Calibration of the GPC column set is performed with 21
narrow molecular weight distribution polystyrene standards with
molecular weights ranging from 580 to 8,400,000, arranged in 6
"cocktail" mixtures with at least a decade of separation between
individual molecular weights. The standards are purchased from
Polymer Laboratories (Shropshire, UK). The polystyrene standards
are prepared at 0.025 grams in 50 milliliters of solvent for
molecular weights equal to or greater than 1,000,000, and 0.05
grams in 50 milliliters of solvent for molecular weights less than
1,000,000. The polystyrene standards are dissolved at 80.degree. C.
with gentle agitation for 30 minutes. The narrow standards mixtures
are run first and in order of decreasing highest molecular weight
component to minimize degradation. The polystyrene standard peak
molecular weights are converted to polyethylene molecular weights
using the following equation (as described in Williams and Ward. J.
Polym. Sci., Polym. Let. 6, 621 (1968)): M.sub.polyethylene=0.431
(M.sub.polystyrene).
[0165] Polyethylene equivalent molecular weight calculations are
performed using Viscotek TriSEC software Version 3.0.
Compression Set
[0166] Compression set is measured according to ASTM D 395. The
sample is prepared by stacking 25.4 mm diameter round discs of 3.2
mm, 2.0 mm, and 0.25 mm thickness until a total thickness of 12.7
mm is reached. The discs are cut from 12.7 cm.times.12.7 cm
compression molded plaques molded with a hot press under the
following conditions: zero pressure for 3 min at 190.degree. C.,
followed by 86 MPa for 2 min at 190.degree. C., followed by cooling
inside the press with cold running water at 86 MPa.
Density
[0167] Samples for density measurement are prepared according to
ASTM D 1928. Measurements are made within one hour of sample
pressing using ASTM D792, Method B.
Flexural/Secant Modulus/Storage Modulus
[0168] Samples are compression molded using ASTM D 1928. Flexural
and 2 percent secant moduli are measured according to ASTM D-790.
Storage modulus is measured according to ASTM D 5026-01 or
equivalent technique.
Optical Properties
[0169] Films of 0.4 mm thickness are compression molded using a hot
press (Carver Model #4095-4PR1001R). The pellets are placed between
polytetrafluoroethylene sheets, heated at 190.degree. C. at 55 psi
(380 kPa) for 3 min followed by 1.3 MPa for 3 min, and then 2.6 MPa
for 3 min. The film is then cooled in the press with running cold
water at 1.3 MPa for 3 min. The compression molded films are used
for optical measurements, tensile behavior, recovery, and stress
relaxation.
[0170] Clarity is measured using BYK Gardner Haze-gard as specified
in ASTM D 1746.
[0171] 45.degree. gloss is measured using BYK Gardner Glossmeter
Microgloss 45.degree. as specified in ASTM D-2457
[0172] Internal haze is measured using BYK Gardner Haze-gard based
on ASTM D 1003 Procedure A. Mineral oil is applied to the film
surface to remove surface scratches.
Mechanical Properties--Tensile, Hysteresis, and Tear
[0173] Stress-strain behavior in uniaxial tension is measured using
ASTM D 1708 microtensile specimens. Samples are stretched with an
Instron at 500% min.sup.-1 at 21.degree. C. Tensile strength and
elongation at break are reported from an average of 5
specimens.
[0174] 100% and 300% Hysteresis is determined from cyclic loading
to 100% and 300% strains using ASTM D 1708 microtensile specimens
with an Instron.TM. instrument. The sample is loaded and unloaded
at 267% min.sup.-1 for 3 cycles at 21.degree. C. Cyclic experiments
at 300% and 80.degree. C. are conducted using an environmental
chamber. In the 80.degree. C. experiment the sample is allowed to
equilibrate for 45 minutes at the test temperature before testing.
In the 21.degree. C. 300% strain cyclic experiment, the retractive
stress at 150% strain from the first unloading cycle is recorded.
Percent recover for all experiments are calculated from the first
unloading cycle using the strain at which the load returned to the
base line. The percent recovery is defined as:
% Recovery = f - s f .times. 100 ##EQU00002##
where .epsilon..sub.f is the strain taken for cyclic loading and
.epsilon..sub.s is the strain where the load returns to the
baseline during the 1.sup.st unloading cycle.
[0175] Stress relaxation is measured at 50 percent strain and
37.degree. C. for 12 hours using an lnstron.TM. instrument equipped
with an environmental chamber. The gauge geometry was 76
mm.times.25 mm.times.0.4 mm. After equilibrating at 37.degree. C.
for 45 min in the environmental chamber, the sample was stretched
to 50% strain at 333% min.sup.-1. Stress was recorded as a function
of time for 12 hours. The percent stress relaxation after 12 hours
was calculated using the formula:
% Stress Relaxation = L 0 - L 12 L 0 .times. 100 ##EQU00003##
where L.sub.0 is the load at 50% strain at 0 time and L.sub.12 is
the load at 50 percent strain after 12 hours.
[0176] Tensile notched tear experiments are carried out on samples
having a density of 0.88 g/cc or less using an Instron.TM.
instrument. The geometry consists of a gauge section of 76
mm.times.13 mm.times.0.4 mm with a 2 mm notch cut into the sample
at half the specimen length. The sample is stretched at 508 mm
min.sup.-1 at 21.degree. C. until it breaks. The tear energy is
calculated as the area under the stress-elongation curve up to
strain at maximum load. An average of at least 3 specimens are
reported.
TMA
[0177] Thermal Mechanical Analysis (Penetration Temperature) is
conducted on 30 mm diameter.times.3.3 mm thick, compression molded
discs formed at 180.degree. C. and 10 MPa molding pressure for 5
minutes and then air quenched. The instrument used is a TMA 7,
brand available from Perkin-Elmer. In the test, a probe with 1.5 mm
radius tip (P/N N519-0416) is applied to the surface of the sample
disc with 1 N force. The temperature is raised at 5.degree. C./min
from 25.degree. C. The probe penetration distance is measured as a
function of temperature. The experiment ends when the probe has
penetrated 1 mm into the sample.
DMA
[0178] Dynamic Mechanical Analysis (DMA) is measured on compression
molded disks formed in a hot press at 180.degree. C. at 10 MPa
pressure for 5 minutes and then water cooled in the press at
90.degree. C./min. Testing is conducted using an ARES controlled
strain rheometer (TA instruments) equipped with dual cantilever
fixtures for torsion testing.
[0179] A 1.5 mm plaque is pressed and cut in a bar of dimensions
32.times.12 mm. The sample is clamped at both ends between fixtures
separated by 10 mm (grip separation .DELTA.L) and subjected to
successive temperature steps from -100.degree. C. to 200.degree. C.
(5.degree. C. per step). At each temperature the torsion modulus G'
is measured at an angular frequency of 10 rad/s, the strain
amplitude being maintained between 0.1 percent and 4 percent to
ensure that the torque is sufficient and that the measurement
remains in the linear regime.
[0180] An initial static force of 10 g is maintained (auto-tension
mode) to prevent slack in the sample when thermal expansion occurs.
As a consequence, the grip separation .DELTA.L increases with the
temperature, particularly above the melting or softening point of
the polymer sample. The test stops at the maximum temperature or
when the gap between the fixtures reaches 65 mm.
Melt Index
[0181] Melt index, or I.sub.2, is measured in accordance with ASTM
D 1238. Condition 190.degree. C./2.16 kg. Melt index, or I.sub.10
is also measured in accordance with ASTM D 1238, Condition
190.degree. C./10 kg.
ATREF
[0182] Analytical temperature rising elution fractionation (ATREF)
analysis is conducted according to the method described in U.S.
Pat. No. 4,798,081 and Wilde, L.; Ryle, T. R.; Knobeloch, D. C.;
Peat, I. R.; Determination of Branching Distributions in
Polyethylene and Ethylene Copolymers, J. Polym. Sci., 20, 441-455
(1982), which are incorporated by reference herein in their
entirety. The composition to be analyzed is dissolved in
trichlorobenzene and allowed to crystallize in a column containing
an inert support (stainless steel shot) by slowly reducing the
temperature to 20.degree. C. at a cooling rate of 0.1.degree.
C./min. The column is equipped with an infrared detector. An ATREF
chromatogram curve is then generated by eluting the crystallized
polymer sample from the column by slowly increasing the temperature
of the eluting solvent (trichlorobenzene) from 20 to 120.degree. C.
at a rate of 1.5.degree. C./min.
.sup.13C NMR Analysis
[0183] The samples are prepared by adding approximately 3 g of a
50/50 mixture of tetrachloroethane-d.sup.2/orthodichlorobenzene to
0.4 g sample in a 10 mm NMR tube. The samples are dissolved and
homogenized by heating the tube and its contents to 150.degree. C.
The data are collected using a JEOL Eclipse.TM. 400 MHz
spectrometer or a Varian Unity Plus.TM. 400 MHz spectrometer,
corresponding to a .sup.13C resonance frequency of 100.5 MHz. The
data are acquired using 4000 transients per data file with a 6
second pulse repetition delay. To achieve minimum signal-to-noise
for quantitative analysis, multiple data files are added together.
The spectral width is 25,000 Hz with a minimum file size of 32K
data points. The samples are analyzed at 130.degree. C. in a 10 mm
broad band probe. The comonomer incorporation is determined using
Randall's triad method (Randall. J. C.; JMS-Rev. Macromol. Chem.
Phys., C29, 201-317 (1989), which is incorporated by reference
herein in its entirety.
Polymer Fractionation by TREF
[0184] Large-scale TREF fractionation is carried by dissolving
15-20 g of polymer in 2 liters of 1,2,4-trichlorobenzene (TCB)by
stirring for 4 hours at 160.degree. C. The polymer solution is
forced by 15 psig (100 kPa) nitrogen onto a 3 inch by 4 foot (7.6
cm.times.12 cm) steel column packed with a 60:40 (v:v) mix of 30-40
mesh (600-425 gm) spherical, technical quality glass beads
(available from Potters Industries, HC 30 Box 20, Brownwood, Tex.,
76801) and stainless steel, 0.028'' (0.7 mm) diameter cut wire shot
(available from Pellets, Inc. 63 Industrial Drive, North Tonawanda,
N.Y., 14120). The column is immersed in a thermally controlled oil
jacket, set initially to 160.degree. C. The column is first cooled
ballistically to 125.degree. C., then slow cooled to 20.degree. C.
at 0.04.degree. C. per minute and held for one hour. Fresh TCB is
introduced at about 65 ml/min while the temperature is increased at
167.degree. C. per minute.
[0185] Approximately 2000 ml portions of eluant from the
preparative TREF column are collected in a 16 station heated
fraction collector. The polymer is concentrated in each fraction
using a rotary evaporator until about 50 to 100 ml of the polymer
solution remains. The concentrated solutions are allowed to stand
overnight before adding excess methanol, filtering, and rinsing
(approx. 300-500 ml of methanol including the final rinse). The
filtration step is performed on a 3 position vacuum assisted
filtering station using 5.0 .mu.m polytetrafluoroethylene coated
filter paper (available from Osmonics Inc., Cat Z50WP04750). The
filtrated fractions are dried overnight in a vacuum oven at
60.degree. C. and weighed on an analytical balance before further
testing.
Melt Strength
[0186] Melt Strength (MS) is measured by using a capillary
rheometer fitted with a 2.1 mm diameter, 20:1 die with an entrance
angle of approximately 45 degrees. After equilibrating the samples
at 190.degree. C. for 10 minutes, the piston is run at a speed of 1
inch/minute (2.54 cm/minute). The standard test temperature is
190.degree. C. The sample is drawn uniaxially to a set of
accelerating nips located 100 mm below the die with an acceleration
of 2.4 mm/sec.sup.2. The required tensile force is recorded as a
function of the take-up speed of the nip rolls. The maximum tensile
force attained during the test is defined as the melt strength. In
the case of polymer melt exhibiting draw resonance, the tensile
force before the onset of draw resonance was taken as melt
strength. The melt strength is recorded in centiNewtons ("cN").
Catalysts
[0187] The term "overnight", if used, refers to a time of
approximately 16-18 hours, the term "room temperature" refers to a
temperature of 20-25.degree. C., and the term "mixed alkanes"
refers to a commercially obtained mixture of C.sub.6-9 aliphatic
hydrocarbons available under the trade designation Isopar E.RTM.,
from ExxonMobil Chemical Company. In the event the name of a
compound herein does not conform to the structural representation
thereof, the structural representation shall control. The synthesis
of all metal complexes and the preparation of all screening
experiments were carried out in a dry nitrogen atmosphere using dry
box techniques. All solvents used were HPLC grade and were dried
before their use. MMAO refers to modified methylalumoxane, a
triisobutylaluminum modified methylalumoxane available commercially
from Akzo-Noble Corporation.
[0188] The preparation of catalyst (B1) is conducted as
follows.
a) Preparation of
(1-methylethyl)(2-hydroxy-3,5-di(t-butyl)phenyl)methylimine
[0189] 3,5-Di-t-butylsalicyladehyde (3.00 g) is added to 10 mL of
isopropylamine. The solution rapidly turns bright yellow. After
stirring at ambient temperature for 3 hours, volatiles are removed
under vacuum to yield a bright yellow, crystalline solid (97
percent yield).
b) Preparation of
1,2-his-(3.5-di-t-butylphenylene)(1-(N-(1-methylethyl)immino)methyl)(2-ox-
oyl) zirconium dibenzyl
[0190] A solution of
(1-methylethyl)(2-hydroxy-3,5-di(t-butyl)phenyl)imine (605 mg, 2.2
mmol) in 5 mL toluene is slowly added to a solution of
Zr(CH.sub.2Ph).sub.4 (500 mg, 1.1 mmol) in 50 mL toluene. The
resulting dark yellow solution is stirred for 30 min. Solvent is
removed under reduced pressure to yield the desired product as a
reddish-brown solid.
[0191] The preparation of catalyst (B2) is conducted as
follows.
a) Preparation of
(1-(2-methylcylclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)imine
[0192] 2-Methylcyclohexylamine (8.44 ml, 64.0 mmol) is dissolved in
methanol (90 mL), and di-t-butylsalicaldehyde (10.00 g, 42.67 mmol)
is added. The reaction mixture is stirred for three hours and then
cooled to -25.degree. C. for 12 hrs. The resulting yellow solid
precipitate is collected by filtration and washed with cold
methanol (2.times.15 mL), and then dried under reduced pressure.
The yield is 11.17 g of a yellow solid. .sup.1H NMR is consistent
with the desired product as a mixture of isomers.
b) Preparation of
bis-(1-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)
immino)zirconium dibenzyl
[0193] A solution of
(1-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)imine
(7.63 g, 23.2 mmol) in 200 mL toluene is slowly added to a solution
of Zr(CH.sub.2Ph).sub.4 (5.28 g, 11.6 mmol) in 600 mL toluene. The
resulting dark yellow solution is stirred for 1 hour at 25.degree.
C. The solution is diluted further with 680 mL toluene to give a
solution having a concentration of 0.00783) M.
[0194] Cocatalyst 1 A mixture of methyldi(C.sub.14-18
alkyl)ammonium salts of tetrakis(pentafluorophenyl)borate
(here-in-after armeenium borate), prepared by reaction of a long
chain trialkylamine (Armeen.TM. M2HT, available from Akzo-Nobel,
Inc.). HCl and Li[B(C.sub.6F.sub.5).sub.4], substantially as
disclosed in U.S. Pat. No. 5,919,9883, Ex. 2.
[0195] Cocatalyst 2 Mixed C.sub.14-18 alkyldimethylammonium salt of
bis(tris(pentafluorophenyl)-alumane)-2-undecylimidazolide, prepared
according to U.S. Pat. No. 6,395,671, Ex. 16.
[0196] Shuttling Agents The shuttling agents employed include
diethylzinc (DEZ, SA1), di(i-butyl)zinc (SA2), di(n-hexyl)zinc
(SA3), triethylaluminum (TEA, SA4), trioctylaluminum (SA5),
triethylgallium (SA6), i-butylaluminum
bis(dimethyl(t-butyl)siloxane) (SA7), i-butylaluminum
bis(di(trimethylsilyl)amide) (SA8), n-octylaluminum
di(pyridine-2-methoxide) (SA9), bis(n-octadecyl)i-butylaluminum
(SA10), i-butylaluminum bis(di(n-pentyl)amide) (SA11),
n-octylaluminum bis(2,6-di-t-butylphenoxide) (SA12),
n-octylaluminum di(ethyl(1-naphthyl)amide) (SA13), ethylaluminum
bis(t-butyldimethylsiloxide) (SA 14), ethylaluminum
di(bis(trimethylsilyl)amide) (SA15), ethylaluminum
bis(2,3,6,7-dibenzo-1-azacycloheptaneamide) (SA16), n-octylaluminum
bis(2,3,6,7-dibenzo-1-azacycloheptaneamide) (SA17), n-octylaluminum
bis(dimethyl(t-butyl)siloxide(SA18), ethylzinc
(2,6-diphenylphenoxide) (SA19), and ethylzinc (t-butoxide)
(SA20).
EXAMPLES 1-4, COMPARATIVE A-C
General High Throughput Parallel Polymerization Conditions
[0197] Polymerizations are conducted using a high throughput,
parallel polymerization reactor (PPR) available from Symyx
Technologies, Inc. and operated substantially according to U.S.
Pat. Nos. 6,248,540, 6,030,917, 6,362,309, 6,306,658, and
6,316,663. Ethylene copolymerizations are conducted at 130.degree.
C. and 200 psi (1.4 MPa) with ethylene on demand using 1.2
equivalents of cocatalyst 1 based on total catalyst used (1.1
equivalents when MMAO is present). A series of polymerizations are
conducted in a parallel pressure reactor (PPR) contained of 48
individual reactor cells in a 6.times.8 array that are fitted with
a pre-weighed glass tube. The working volume in each reactor cell
is 6000 .mu.L. Each cell is temperature and pressure controlled
with stirring provided by individual stirring paddles. The monomer
gas and quench gas are plumbed directly into the PPR unit and
controlled by automatic valves. Liquid reagents are robotically
added to each reactor cell by syringes and the reservoir solvent is
mixed alkanes. The order of addition is mixed alkanes solvent (4
ml), ethylene, 1-octene comonomer (1 ml), cocatalyst 1 or
cocatalyst 1/MMAO mixture, shuttling agent, and catalyst or
catalyst mixture. When a mixture of cocatalyst 1 and MMAO or a
mixture of two catalysts is used, the reagents are premixed in a
small vial immediately prior to addition to the reactor. When a
reagent is omitted in an experiment, the above order of addition is
otherwise maintained. Polymerizations are conducted for
approximately 1-2 minutes, until predetermined ethylene
consumptions are reached. After quenching with CO, the reactors are
cooled and the glass tubes are unloaded. The tubes are transferred
to a centrifuge/vacuum drying unit, and dried for 12 hours at
60.degree. C. The tubes containing dried polymer are weighed and
the difference between this weight and the tare weight gives the
net yield of polymer. Results are contained in Table 1. In Table 1
and elsewhere in the application, comparative compounds are
indicated by an asterisk (*).
[0198] Examples 1-4 demonstrate the synthesis of linear block
copolymers by the present invention as evidenced by the formation
of a very narrow MWD, essentially monomodal copolymer when DEZ is
present and a bimodal, broad molecular weight distribution product
(a mixture of separately produced polymers) in the absence of DEZ.
Due to the fact that Catalyst (A1) is known to incorporate more
octene than Catalyst (B1), the different blocks or segments of the
resulting copolymers of the invention are distinguishable based on
branching or density.
TABLE-US-00001 TABLE 1 Cat. (A1) Cat (B1) Cocat MMAO shuttling Ex.
(.mu.mol) (.mu.mol) (.mu.mol) (.mu.mol) agent (.mu.mol) Yield (g)
Mn Mw/Mn hexyls.sup.1 A* 0.06 -- 0.066 0.3 -- 0.1363 300502 3.32 --
B* -- 0.1 0.110 0.5 -- 0.1581 36957 1.22 2.5 C* 0.06 0.1 0.176 0.8
-- 0.2038 45526 5.30.sup.2 5.5 1 0.06 0.1 0.192 -- DEZ (8.0) 0.1974
28715 1.19 4.8 2 0.06 0.1 0.192 -- DEZ (80.0) 0.1468 2161 1.12 14.4
3 0.06 0.1 0.192 -- TEA (8.0) 0.208 22675 1.71 4.6 4 0.06 0.1 0.192
-- TEA (80.0) 0.1879 3338 1.54 9.4 .sup.1C.sub.6 or higher chain
content per 1000 carbons .sup.2Bimodal molecular weight
distribution
[0199] It may be seen the polymers produced according to the
invention have a relatively narrow polydispersity (Mw/Mn) and
larger block-copolymer content (trimer, tetramer, or larger) than
polymers prepared in the absence of the shuttling agent.
[0200] Further characterizing data for the polymers of Table 1 are
determined by reference to the figures. More specifically DSC and
ATREF results show the following:
[0201] The DSC curve for the polymer of example 1 shows a
115.7.degree. C. melting point (Tm) with a heat of fusion of 158.1
J/g. The corresponding CRYSTAF curve shows the tallest peak at
34.5.degree. C. with a peak area of 52.9 percent. The difference
between the DSC Tm and the Tcrystaf is 81.2.degree. C.
[0202] The DSC curve for the polymer of example 2 shows a peak with
a 109.7.degree. C. melting point (Tm) with a heat of fusion of
214.0 J/g. The corresponding CRYSTAF curve shows the tallest peak
at 46.2.degree. C. with a peak area of 57.0 percent. The difference
between the DSC Tm and the Tcrystaf is 63.5.degree. C.
[0203] The DSC curve for the polymer of example 3 shows a peak with
a 120.7.degree. C. melting point (Tm) with a heat of fusion of
160.1 J/g. The corresponding CRYSTAF curve shows the tallest peak
at 66.1.degree. C. with a peak area of 71.8 percent. The difference
between the DSC Tm and the Tcrystaf is 54.6.degree. C.
[0204] The DSC curve for the polymer of example 4 shows a peak with
a 104.5.degree. C. melting point (Tm) with a heat of fusion of
170.7 .mu.J/g. The corresponding CRYSTAF curve shows the tallest
peak at 30.degree. C. with a peak area of 18.2 percent. The
difference between the DSC Tm and the Tcrystaf is 74.5.degree.
C.
[0205] The DSC curve for comparative A shows a 90.0.degree. C.
melting point (Tm) with a heat of fusion of 86.7 J/g. The
corresponding CRYSTAF curve shows the tallest peak at 48.5.degree.
C. with a peak area of 29.4 percent. Both of these values are
consistent with a resin that is low in density. The difference
between the DSC Tm and the Tcrystaf is 41.8.degree. C.
[0206] The DSC curve for comparative B shows a 129.8.degree. C.
melting point (Tm) with a heat of fusion of 237.0 .mu.J/g. The
corresponding CRYSTAF curve shows the tallest peak at 82.4.degree.
C. with a peak area of 83.7 percent. Both of these values are
consistent with a resin that is high in density. The difference
between the DSC Tm and the Tcrystaf is 47.4.degree. C.
[0207] The DSC curve for comparative C shows a 125.3.degree. C.
melting point (Tm) with a heat of fusion of 143.0 .mu.J/g. The
corresponding CRYSTAF curve shows the tallest peak at 81.8.degree.
C. with a peak area of 34.7 percent as well as a lower crystalline
peak at 52.4.degree. C. The separation between the two peaks is
consistent with the presence of a high crystalline and a low
crystalline polymer. The difference between the DSC Tm and the
Tcrystaf is 43.5.degree. C.
EXAMPLES 5-19
Comparatives D-F, Continuous Solution Polymerization, Catalyst
A1/B2+DEZ
[0208] Continuous solution polymerizations are carried out in a
computer controlled autoclave reactor equipped with an internal
stirrer. Purified mixed alkanes solvent (Isopar.TM. E available
from ExxonMobil Chemical Company) ethylene at 2.70 lbs/hour (1.22
kg/hour), 1-octene, and hydrogen (where used) are supplied to a 3.8
L reactor equipped with a jacket for temperature control and an
internal thermocouple. The solvent feed to the reactor is measured
by a mass-flow controller. A variable speed diaphragm pump controls
the solvent flow rate and pressure to the reactor. At the discharge
of the pump, a side stream is taken to provide flush flows for the
catalyst and cocatalyst 1 injection lines and the reactor agitator.
These flows are measured by Micro-Motion mass flow meters and
controlled by control valves or by the manual adjustment of needle
valves. The remaining solvent is combined with 1-octene, ethylene,
and hydrogen (where used) and fed to the reactor. A mass flow
controller is used to deliver hydrogen to the reactor as needed.
The temperature of the solvent/monomer solution is controlled by
use of a heat exchanger before entering the reactor. This stream
enters the bottom of the reactor. The catalyst component solutions
are metered using pumps and mass flow meters and are combined with
the catalyst flush solvent and introduced into the bottom of the
reactor. The reactor is run liquid-full at 500 psig (3.45 MPa) with
vigorous stirring. Product is removed through exit lines at the top
of the reactor. All exit lines from the reactor are steam traced
and insulated. Polymerization is stopped by the addition of a small
amount of water into the exit line along with any stabilizers or
other additives and passing the mixture through a static mixer. The
product stream is then heated by passing through a heat exchanger
before devolatilization. The polymer product is recovered by
extrusion using a devolatilizing extruder and water cooled
pelletizer. Process details and results are contained in Table 2.
Selected polymer properties are provided in Table 3.
TABLE-US-00002 TABLE 2 Process details for preparation of exemplary
polymers Cat Cat A1 Cat B2 DEZ Cocat Cocat Poly C.sub.8H.sub.16
Solv. H.sub.2 A1.sup.2 Flow B2.sup.3 Flow DEZ Flow Conc. Flow
[C.sub.2H.sub.4]/ Rate.sup.5 Conv Ex. kg/hr kg/hr sccm.sup.1 T
.degree. C. ppm kg/hr ppm kg/hr Conc % kg/hr ppm kg/hr [DEZ].sup.4
kg/hr %.sup.6 Solids % Eff..sup.7 D* 1.63 12.7 29.90 120 142.2 0.14
-- -- 0.19 0.32 820 0.17 536 1.81 88.8 11.2 95.2 E* '' 9.5 5.00 ''
-- -- 109 0.10 0.19 '' 1743 0.40 485 1.47 89.9 11.3 126.8 F* ''
11.3 251.6 '' 71.7 0.06 30.8 0.06 -- -- '' 0.11 -- 1.55 88.5 10.3
257.7 5 '' '' -- '' '' 0.14 30.8 0.13 0.17 0.43 '' 0.26 419 1.64
89.6 11.1 118.3 6 '' '' 4.92 '' '' 0.10 30.4 0.08 0.17 0.32 '' 0.18
570 1.65 89.3 11.1 172.7 7 '' '' 21.70 '' '' 0.07 30.8 0.06 0.17
0.25 '' 0.13 718 1.60 89.2 10.6 244.1 8 '' '' 36.90 '' '' 0.06 ''
'' '' 0.10 '' 0.12 1778 1.62 90.0 10.8 261.1 9 '' '' 78.43 '' '' ''
'' '' '' 0.04 '' '' 4596 1.63 90.2 10.8 267.9 10 '' '' 0.00 123
71.1 0.12 30.3 0.14 0.34 0.19 1743 0.08 415 1.67 90.31 11.1 131.1
11 '' '' '' 120 71.1 0.16 '' 0.17 0.80 0.15 1743 0.10 249 1.68
89.56 11.1 100.6 12 '' '' '' 121 71.1 0.15 '' 0.07 '' 0.09 1743
0.07 396 1.70 90.02 11.3 137.0 13 '' '' '' 122 71.1 0.12 '' 0.06 ''
0.05 1743 0.05 653 1.69 89.64 11.2 161.9 14 '' '' '' 120 71.1 0.05
'' 0.29 '' 0.10 1743 0.10 395 1.41 89.42 9.3 114.1 15 2.45 '' '' ''
71.1 0.14 '' 0.17 '' 0.14 1743 0.09 282 1.80 89.33 11.3 121.3 16 ''
'' '' 122 71.1 0.10 '' 0.13 '' 0.07 1743 0.07 485 1.78 90.11 11.2
159.7 17 '' '' '' 121 71.1 0.10 '' 0.14 '' 0.08 1743 '' 506 1.75
89.08 11.0 155.6 18 0.69 '' '' 121 71.1 '' '' 0.22 '' 0.11 1743
0.10 331 1.25 89.93 8.8 90.2 19 0.32 '' '' 122 71.1 0.06 '' '' ''
0.09 1743 0.08 367 1.16 90.74 8.4 106.0 *Comparative, not an
example of the invention .sup.1standard cm.sup.3/min
.sup.2[N-(2,6-di(1-methylethyl)phenyl)amido)(2-isopropylphenyl)(.alpha.-na-
phthalen-2-diyl(6-pyridin-2-diyl)methane)]hafnium dimethyl
.sup.3bis-(1-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)immi-
no) zirconium dibenzyl .sup.4molar ratio in reactor .sup.5polymer
production rate .sup.6percent ethylene conversion in reactor
.sup.7efficiency, kg polymer/g M where g M = g Hf + g Zr
TABLE-US-00003 TABLE 3 Properties of exemplary polymers Heat of
CRYSTAF Density Mw Mn Fusion T.sub.m T.sub.c T.sub.CRYSTAF T.sub.m
- T.sub.CRYSTAF Peak Area Ex. (g/cm.sup.3) I.sub.2 I.sub.10
I.sub.10/I.sub.2 (g/mol) (g/mol) Mw/Mn (J/g) (.degree. C.)
(.degree. C.) (.degree. C.) (.degree. C.) (percent) D* 0.8627 1.5
10.0 6.5 110,000 55,800 2.0 32 37 45 30 7 99 E* 0.9378 7.0 39.0 5.6
65,000 33,300 2.0 183 124 113 79 45 95 F* 0.8895 0.9 12.5 13.4
137,300 9,980 13.8 90 125 111 78 47 20 5 0.8786 1.5 9.8 6.7 104,600
53,200 2.0 55 120 101 48 72 60 6 0.8785 1.1 7.5 6.5 109600 53300
2.1 55 115 94 44 71 63 7 0.8825 1.0 7.2 7.1 118,500 53,100 2.2 69
121 103 49 72 29 8 0.8828 0.9 6.8 7.7 129,000 40,100 3.2 68 124 106
80 43 13 9 0.8836 1.1 9.7 9.1 129600 28700 4.5 74 125 109 81 44 16
10 0.8784 1.2 7.5 6.5 113,100 58,200 1.9 54 116 92 41 75 52 11
0.8818 9.1 59.2 6.5 66,200 36,500 1.8 63 114 93 40 74 25 12 0.8700
2.1 13.2 6.4 101,500 55,100 1.8 40 113 80 30 83 91 13 0.8718 0.7
4.4 6.5 132,100 63,600 2.1 42 114 80 30 81 8 14 0.9116 2.6 15.6 6.0
81,900 43,600 1.9 123 121 106 73 48 92 15 0.8719 6.0 41.6 6.9
79,900 40,100 2.0 33 114 91 32 82 10 16 0.8758 0.5 3.4 7.1 148,500
74,900 2.0 43 117 96 48 69 65 17 0.8757 1.7 11.3 6.8 107,500 54,000
2.0 43 116 96 43 73 57 18 0.9192 4.1 24.9 6.1 72,000 37,900 1.9 136
120 106 70 50 94 19 0.9344 3.4 20.3 6.0 76,800 39,400 1.9 169 125
112 80 45 88
[0209] The resulting polymers are tested by DSC and ATREF as with
previous examples. Results are as follows:
[0210] The DSC curve for the polymer of example 5 shows a peak with
a 119.6.degree. C. melting point (Tm) with a heat of fusion of 60.0
J/g. The corresponding CRYSTAF curve shows the tallest peak at
47.6.degree. C. with a peak area of 59.5 percent. The delta between
the DSC Tm and the Tcrystaf is 72.0.degree. C.
[0211] The DSC curve for the polymer of example 6 shows a peak with
a 115.2.degree. C. melting point (Tm) with a heat of fusion of 60.4
J/g. The corresponding CRYSTAF curve shows the tallest peak at
44.2.degree. C. with a peak area of 62.7 percent. The delta between
the DSC Tm and the Tcrystaf is 71.0.degree. C.
[0212] The DSC curve for the polymer of example 7 shows a peak with
a 121.3.degree. C. melting point with a heat of fusion of 69.1 J/g.
The corresponding CRYSTAF curve shows the tallest peak at
49.2.degree. C. with a peak area of 29.4 percent. The delta between
the DSC Tm and the Tcrystaf is 72.1.degree. C.
[0213] The DSC curve for the polymer of example 8 shows a peak with
a 123.5.degree. C. melting point (Tm) with a heat of fusion of 67.9
J/g. The corresponding CRYSTAF curve shows the tallest peak at
80.1.degree. C. with a peak area of 12.7 percent. The delta between
the DSC Tm and the Tcrystaf is 43.4.degree. C.
[0214] The DSC curve for the polymer of example 9 shows a peak with
a 124.6.degree. C. melting point (Tm) with a heat of fusion of 73.5
J/g. The corresponding CRYSTAF curve shows the tallest peak at
80.8.degree. C. with a peak area of 16.0 percent. The delta between
the DSC Tm and the Tcrystaf is 43.8.degree. C.
[0215] The DSC curve for the polymer of example 10 shows a peak
with a 115.6.degree. C. melting point (Tm) with a heat of fusion of
60.7 J/g. The corresponding CRYSTAF curve shows the tallest peak at
40.9.degree. C. with a peak area of 52.4 percent. The delta between
the DSC Tm and the Tcrystaf is 74.7.degree. C.
[0216] The DSC curve for the polymer of example 11 shows a peak
with a 113.6.degree. C. melting point (Tm) with a heat of fusion of
70.4 J/g. The corresponding CRYSTAF curve shows the tallest peak at
39.60.degree. C. with a peak area of 25.2 percent. The delta
between the DSC Tm and the Tcrystaf is 74.1.degree. C.
[0217] The DSC curve for the polymer of example 12 shows a peak
with a 113.2.degree. C. melting point (Tm) with a heat of fusion of
48.9 J/g. The corresponding CRYSTAF curve shows no peak equal to or
above 30.degree. C. (Tcrystaf for purposes of further calculation
is therefore set at 30.degree. C.). The delta between the DSP Tm
and the Tcrystaf is 83.2.degree. C.
[0218] The DSC curve for the polymer of example 13 shows a peak
with a 114.4.degree. C. melting point (Tm) with a heat of fusion of
49.4 J/g. The corresponding CRYSTAF curve shows the tallest peak at
33.8.degree. C. with a peak area of 7.7 percent. The delta between
the DSC Tm and the Tcrystaf is 84.4.degree. C.
[0219] The DSC for the polymer of example 14 shows a peak with a
120.8.degree. C. melting point (Tm) with a heat of fusion of 127.9
J/g. The corresponding CRYSTAF curve shows the tallest peak at
72.9.degree. C. with a peak area of 92.2 percent. The delta between
the DSC Tm and the Tcrystaf is 47.9.degree. C.
[0220] The DSC curve for the polymer of example 15 shows a peak
with a 114.3.degree. C. melting point (Tm) with a heat of fusion of
36.2 J/g. The corresponding CRYSTAF curve shows the tallest peak at
32.3.degree. C. with a peak area of 9.8 percent. The delta between
the DSP Tm and the Tcrystaf is 82.0.degree. C.
[0221] The DSC curve for the polymer of example 16 shows a peak
with a 116.6.degree. C. melting point (Tm) with a heat of fusion of
44.9 J/g. The corresponding CRYSTAF curve shows the tallest peak at
48.0.degree. C. with a peak area of 65.0 percent. The delta between
the DSC Tm and the Tcrystaf is 68.6.degree. C.
[0222] The DSC curve for the polymer of example 17 shows a peak
with a 116.0.degree. C. melting point (Tm) with a heat of fusion of
47.0 J/g. The corresponding CRYSTAF curve shows the tallest peak at
43.1.degree. C. with a peak area of 56.8 percent. The delta between
the DSC Tm and the Tcrystaf is 72.9.degree. C.
[0223] The DSC curve for the polymer of example 18 shows a peak
with a 120.5.degree. C. melting point (Tm) with a heat of fusion of
141.8 J/g. The corresponding CRYSTAF curve shows the tallest peak
at 70.0.degree. C. with a peak area of 94.0 percent. The delta
between the DSC Tm and the Tcrystaf is 50.5.degree. C.
[0224] The DSC curve for the polymer of example 19 shows a peak
with a 124.8.degree. C. melting point (Tm) with a heat of fusion of
174.8 J/g. The corresponding CRYSTAF curve shows the tallest peak
at 79.9.degree. C. with a peak area of 87.9 percent. The delta
between the DSC Tm and the Tcrystaf is 45.0.degree. C.
[0225] The DSC curve for the polymer of comparative D shows a peak
with a 37.3.degree. C. melting point (Tm) with a heat of fusion of
31.6 J/g. The corresponding CRYSTAF curve shows no peak equal to
and above 30.degree. C. Both of these values are consistent with a
resin that is low in density. The delta between the DSC Tm and the
Tcrystaf is 7.3.degree. C.
[0226] The DSC curve for the polymer of comparative E shows a peak
with a 124.0.degree. C. melting point (Tm) with a heat of fusion of
179.3 J/g. The corresponding CRYSTAF curve shows the tallest peak
at 79.3.degree. C. with a peak area of 94.6 percent. Both of these
values are consistent with a resin that is high in density. The
delta between the DSC Tm and the Tcrystaf is 44.6.degree. C.
[0227] The DSC curve for the polymer of comparative F shows a peak
with a 124.8.degree. C. melting point (Tm) with a heat of fusion of
90.4 flag. The corresponding CRYSTAF curve shows the tallest peak
at 77.6.degree. C. with a peak area of 19.5 percent. The separation
between the two peaks is consistent with the presence of both a
high crystalline and a low crystalline polymer. The delta between
the DSC Tm and the Tcrystaf is 47.2.degree. C.
Physical Property Testing
[0228] Polymer samples are evaluated for physical properties such
as high temperature resistance properties, as evidenced by TMA
temperature testing pellet blocking strength, high temperature
recovery, high temperature compression set and storage modulus
ratio, G'(25.degree. C.)/G'(100.degree. C.). Several commercially
available polymers are included in the tests: Comparative G* is a
substantially linear ethylene/1-octene copolymer (AFFINITY.RTM.,
available from the Dow Chemical Company), Comparative H* is an
elastomeric, substantially linear ethylene/1-octene copolymer
(AFFINITY.RTM. EG8100, available from The Dow Chemical Company),
Comparative 1 is a substantially linear ethylene/1-octene copolymer
(AFFINITY.RTM. PL 1840, available from The Dow Chemical Company),
Comparative J is a hydrogenated styrene/butadiene/styrene triblock
copolymer (KRATON.TM. G1652, available from KRATON Polymers),
Comparative K is a thermoplastic vulcanizate (TPV, a polyolefin
blend containing dispersed therein a crosslinked elastomer).
Results are presented in Table 4.
TABLE-US-00004 TABLE 4 High Temperature Mechanical Properties 300%
Pellet Strain TMA-1 mm Blocking Recovery Compression penetration
Strength G'(25.degree. C.)/ (80.degree. C.) Set (70.degree. C.) Ex.
(.degree. C.) lb/ft.sup.2 (kPa) G'(100.degree. C.) (percent)
(percent) D* 51 -- 9 Failed -- E* 130 -- 18 -- -- F* 70 141 (6.8) 9
Failed 100 5 104 0 (0) 6 81 49 6 110 -- 5 -- 52 7 113 -- 4 84 43 8
111 -- 4 Failed 41 9 97 -- 4 -- 66 10 108 -- 5 81 55 11 100 -- 8 --
68 12 88 -- 8 -- 79 13 95 -- 6 84 71 14 125 -- 7 -- -- 15 96 -- 5
-- 58 16 113 -- 4 -- 42 17 108 0 (0) 4 82 47 18 125 -- 10 -- -- 19
133 -- 9 -- -- G* 75 463 (22.2) 89 Failed 100 H* 70 213 (10.2) 29
Failed 100 I* 111 -- 11 -- -- J* 107 -- 5 Failed 100 K* 152 -- 3 --
40
[0229] In Table 4, Comparative F (which is a physical blend of the
two polymers resulting from simultaneous polymerizations using
catalyst A1 and B1) has a 1 mm penetration temperature of about
70.degree. C. while Examples 5-9 have a 1 mm penetration
temperature of 100.degree. C. or greater. Further, examples 10-19
all have a 1 mm penetration temperature of greater than 85.degree.
C., with most having 1 mm TMA temperature of greater than
90.degree. C. or even greater than 100.degree. C. This shows that
the novel polymers have better dimensional stability at higher
temperatures compared to a physical blend. Comparative J (a
commercial SEBS) has a good 1 mm TMA temperature of about
107.degree. C., but it has very poor (high temperature 70.degree.
C.) compression set of about 100 percent and it also failed to
recover (sample broke) during a high temperature (80.degree. C.)
300 percent strain recover. Thus the exemplified polymers have a
unique combination of properties unavailable even in some
commercially available, high performance thermoplastic
elastomers.
[0230] Similarly. Table 4 shows a low (good) storage modulus ratio,
G'(25.degree. C.)/G(100.degree. C.), for the inventive polymers of
6 or less, whereas a physical blend (Comparative F) has a storage
modulus ratio of 9 and a random ethylene/octene copolymer
(Comparative G) of similar density has a storage modulus ratio an
order of magnitude greater (89). It is desirable that the storage
modulus ratio of a polymer be as close to 1 as possible. Such
polymers will be relatively unaffected by temperature, and
fabricated articles made from such polymers can be usefully
employed over a broad temperature range. This feature of low
storage modulus ratio and temperature independence is particularly
useful in elastomer applications such as in pressure sensitive
adhesive formulations.
[0231] The data in Table 4 also demonstrate that the polymers of
the invention possess improved pellet blocking strength. In
particular, Example 5 has a pellet blocking strength of 0 MPa,
meaning it is free flowing under the conditions tested, compared to
Comparatives F and G which show considerable blocking. Blocking
strength is important since bulk shipment of polymers having large
blocking strengths can result in product clumping or sticking
together upon storage or shipping, resulting in poor handling
properties.
[0232] High temperature (70.degree. C.) compression set for the
inventive polymers is generally good, meaning generally less than
about 80 percent, preferably less than about 70 percent and
especially less than about 60 percent. In contrast. Comparatives F,
G, H and J all have a 70.degree. C. compression set of 100 percent
(the maximum possible value, indicating no recovery). Good high
temperature compression set (low numerical values) is especially
needed for applications such as gaskets, window profiles, o-rings,
and the like.
TABLE-US-00005 TABLE 5 Ambient Temperature Mechanical Properties
Tensile 100% 300% Retractive Elon- Abrasion: Notched Strain Strain
Stress Com- Stress Flex Tensile Tensile Elongation Tensile gation
Volume Tear Recovery Recovery at 150% pression Relaxation Modulus
Modulus Strength at Break.sup.1 Strength at Break Loss Strength
21.degree. C. 21.degree. C. Strain Set 21.degree. C. at 50% Ex.
(MPa) (MPa) (MPa).sup.1 (%) (MPa) (%) (mm.sup.3) (mJ) (percent)
(percent) (kPa) (Percent) Strain.sup.2 D* 12 5 -- -- 10 1074 -- --
91 83 760 -- -- E* 895 589 -- 31 1029 -- -- -- -- -- -- -- F* 57 46
-- -- 12 824 93 339 78 65 400 42 -- 5 30 24 14 951 16 1116 48 -- 87
74 790 14 33 6 33 29 -- -- 14 938 -- -- -- 75 861 13 -- 7 44 37 15
846 14 854 39 -- 82 73 810 20 -- 8 41 35 13 785 14 810 45 461 82 74
760 22 -- 9 43 38 -- -- 12 823 -- -- -- -- -- 25 -- 10 23 23 -- --
14 902 -- -- 86 75 860 12 -- 11 30 26 -- -- 16 1090 -- 976 89 66
510 14 30 12 20 17 12 961 13 931 -- 1247 91 75 700 17 -- 13 16 14
-- -- 13 814 -- 691 91 -- -- 21 -- 14 212 160 -- -- 29 857 -- -- --
-- -- -- -- 15 18 14 12 1127 10 1573 -- 2074 89 83 770 14 -- 16 23
20 -- -- 12 968 -- -- 88 83 1040 13 -- 17 20 18 -- -- 13 1252 --
1274 13 83 920 4 -- 18 323 239 -- -- 30 808 -- -- -- -- -- -- -- 19
706 483 -- -- 36 871 -- -- -- -- -- -- -- G* 15 15 -- -- 17 1000 --
746 86 53 110 27 50 H* 16 15 -- -- 15 829 -- 569 87 60 380 23 -- I*
210 147 -- -- 29 697 -- -- -- -- -- -- -- J* -- -- -- -- 32 609 --
-- 93 96 1900 25 -- K* -- -- -- -- -- -- -- -- -- -- -- 30 --
.sup.1Tested at 51 cm/minute .sup.2measured at 38.degree. C. for 12
hours
[0233] Table 5 shows results for mechanical properties for the new
polymers as well as for various comparison polymers at ambient
temperatures. It may be seen that the inventive polymers have very
good abrasion resistance when tested according to ISO 4649,
generally showing a volume loss of less than about 90 mm.sup.3
preferably less than about 80 mm.sup.3 and especially less than
about 50 mm.sup.3. In this test, higher numbers indicate higher
volume loss and consequently lower abrasion resistance.
[0234] Tear strength as measured by tensile notched tear strength
of the inventive polymers is generally 1000 mJ or higher, as shown
in Table 5. Tear strength for the inventive polymers can be as high
as 3000 mJ, or even as high as 5000 mJ. Comparative polymers
generally have tear strengths no higher than 750 mJ.
[0235] Table 5 also shows that the polymers of the invention have
better retractive stress at 150 percent strain (demonstrated by
higher retractive stress values) than some of the comparative
samples. Comparative Examples F, G and H have retractive stress
value at 150 percent strain of 400 kPa or less, while the inventive
polymers have retractive stress values at 150 percent strain of 500
kPa (Ex. 11) to as high as about 1100 kPa (Ex. 17). Polymers having
higher than 150 percent retractive stress values would be quite
useful for elastic applications, such as elastic fibers and
fabrics, especially nonwoven fabrics. Other applications include
diaper, hygiene, and medical garment waistband applications, such
as tabs and elastic bands.
[0236] Table 5 also shows that stress relaxation (at 50 percent
strain) is also improved (less) for the inventive polymers as
compared to, for example, Comparative G. Lower stress relaxation
means that the polymer retains its force better in applications
such as diapers and other garments where retention of elastic
properties over long time periods at body temperatures is
desired.
TABLE-US-00006 TABLE 6 Polymer Optical Properties Ex. Internal Haze
(percent) Clarity (percent) 45.degree. Gloss (percent) F* 84 22 49
G* 5 73 56 5 13 72 60 6 33 69 53 7 28 57 59 8 20 65 62 9 61 38 49
10 15 73 67 11 13 69 67 12 8 75 72 13 7 74 69 14 59 15 62 15 11 74
66 16 39 70 65 17 29 73 66 18 61 22 60 19 74 11 52 G* 5 73 56 H* 12
76 59 I* 20 75 59
[0237] The optical properties reported in Table 6 are based on
compression molded films substantially lacking in orientation.
Optical properties of the polymers may be varied over wide ranges,
due to variation in crystallite size, resulting from variation in
the quantity of chain shutting agent employed in the
polymerization.
Extraction of Multi-Block Copolymers
[0238] Extraction studies of the polymers of examples 5, 7 and
Comparative E are conducted. In the experiments, the polymer sample
is weighed into a glass fritted extraction thimble and fitted into
a Kumagawa type extractor. The extractor with sample is purged with
nitrogen, and a 500 mL round bottom flask is charged with 350 mL of
diethyl ether. The flask is then fitted to the extractor. The ether
is heated while being stirred. Time is noted when the ether begins
to condense into the thimble, and the extraction is allowed to
proceed under nitrogen for 24 hours. At this time, heating is
stopped and the solution is allowed to cool. Any ether remaining in
the extractor is returned to the flask. The ether in the flask is
evaporated under vacuum at ambient temperature, and the resulting
solids are purged dry with nitrogen. Any residue is transferred to
a weighed bottle using successive washes of hexane. The combined
hexane washes are then evaporated with another nitrogen purge, and
the residue dried under vacuum overnight at 40.degree. C. Any
remaining ether in the extractor is purged dry with nitrogen.
[0239] A second clean round bottom flask charged with 350 mL of
hexane is then connected to the extractor. The hexane is heated to
reflux with stirring and maintained at reflux for 24 hours after
hexane is first noticed condensing into the thimble. Heating is
then stopped and the flask is allowed to cool. Any hexane remaining
in the extractor is transferred back to the flask. The hexane is
removed by evaporation under vacuum at ambient temperature, and any
residue remaining in the flask is transferred to a weighed bottle
using successive hexane washes. The hexane in the flask is
evaporated by a nitrogen purge, and the residue is vacuum dried
overnight at 40.degree. C.
[0240] The polymer sample remaining in the thimble after the
extractions is transferred from the thimble to a weighed bottle and
vacuum dried overnight at 40.degree. C. Results are contained in
Table 7.
TABLE-US-00007 TABLE 7 ether ether C.sub.8 hexane hexane C.sub.8
residue wt. soluble soluble mole soluble soluble mole C.sub.8 mole
Sample (g) (g) (percent) percent.sup.1 (g) (percent) percent.sup.1
percent.sup.1 Comp. 1.097 0.063 5.69 12.2 0.245 22.35 13.6 6.5 F*
Ex. 5 1.006 0.041 4.08 -- 0.040 3.98 14.2 11.6 Ex. 7 1.092 0.017
1.59 13.3 0.012 1.10 11.7 9.9 .sup.1Determined by .sup.13C NMR
Additional Polymer Examples 19A-J, Continuous Solution
Polymerization, Catalyst A1/B2+DEZ
FOR EXAMPLES 19A-I
[0241] Continuous solution polymerizations are carried out in a
computer controlled well-mixed reactor. Purified mixed alkanes
solvent (Isopar.TM. E available from Exxon Mobil, Inc.), ethylene,
1-octene, and hydrogen (where used) are combined and fed to a 27
gallon reactor. The feeds to the reactor are measured by mass-flow
controllers. The temperature of the feed stream is controlled by
use of a glycol cooled heat exchanger before entering the reactor.
The catalyst component solutions are metered using pumps and mass
flow meters. The reactor is run liquid-full at approximately 550
psig pressure. Upon exiting the reactor, water and additive are
injected in the polymer solution. The water hydrolyzes the
catalysts, and terminates the polymerization reactions. The post
reactor solution is then heated in preparation for a two-stage
devolatization. The solvent and unreacted monomers are removed
during the devolatization process. The polymer melt is pumped to a
die for underwater pellet cutting.
FOR EXAMPLE 19J
[0242] Continuous solution polymerizations are carried out in a
computer controlled autoclave reactor equipped with an internal
stirrer. Purified mixed alkanes solvent (Isopar.TM. E available
from ExxonMobil Chemical Company), ethylene at 2.70 lbs/hour (1.22
kg/hour), 1-octene, and hydrogen (where used) are supplied to a 3.8
L reactor equipped with a jacket for temperature control and an
internal thermocouple. The solvent feed to the reactor is measured
by a mass-flow controller. A variable speed diaphragm pump controls
the solvent flow rate and pressure to the reactor. At the discharge
of the pump, a side stream is taken to provide flush flows for the
catalyst and cocatalyst injection lines and the reactor agitator.
These flows are measured by Micro-Motion mass flow meters and
controlled by control valves or by the manual adjustment of needle
valves. The remaining solvent is combined with 1-octene, ethylene,
and hydrogen (where used) and fed to the reactor. A mass flow
controller is used to deliver hydrogen to the reactor as needed.
The temperature of the solvent/monomer solution is controlled by
use of a heat exchanger before entering the reactor. This stream
enters the bottom of the reactor. The catalyst component solutions
are metered using pumps and mass flow meters and are combined with
the catalyst flush solvent and introduced into the bottom of the
reactor. The reactor is run liquid-full at 500 psig (3.45 MPa) with
vigorous stirring. Product is removed through exit lines at the top
of the reactor. All exit lines from the reactor are steam traced
and insulated. Polymerization is stopped by the addition of a small
amount of water into the exit line along with any stabilizers or
other additives and passing the mixture through a static mixer. The
product stream is then heated by passing through a heat exchanger
before devolatilization. The polymer product is recovered by
extrusion using a devolatilizing extruder and water cooled
pelletizer.
[0243] Process details and results are contained in Table 8.
Selected polymer properties are provided in Tables 9A-C.
[0244] In Table 9B, inventive examples 19F and 19G show low
immediate set of around 65-70% strain after 500% elongation.
TABLE-US-00008 TABLE 8 Polymerization Conditions Cat Cat Cat
A1.sup.2 Cat A1 B2.sup.3 B2 DEZ DEZ C.sub.2H.sub.4 C.sub.8H.sub.16
Solv. H.sub.2 T Conc. Flow Conc. Flow Conc Flow Ex. lb/hr lb/hr
lb/hr sccm.sup.1 .degree. C. ppm lb/hr ppm lb/hr wt % lb/hr 19A
55.29 32.03 323.03 101 120 600 0.25 200 0.42 3.0 0.70 19B 53.95
28.96 325.3 577 120 600 0.25 200 0.55 3.0 0.24 19C 55.53 30.97
324.37 550 120 600 0.216 200 0.609 3.0 0.69 19D 54.83 30.58 326.33
60 120 600 0.22 200 0.63 3.0 1.39 19E 54.95 31.73 326.75 251 120
600 0.21 200 0.61 3.0 1.04 19F 50.43 34.80 330.33 124 120 600 0.20
200 0.60 3.0 0.74 19G 50.25 33.08 325.61 188 120 600 0.19 200 0.59
3.0 0.54 19H 50.15 34.87 318.17 58 120 600 0.21 200 0.66 3.0 0.70
19I 55.02 34.02 323.59 53 120 600 0.44 200 0.74 3.0 1.72 19J 7.46
9.04 50.6 47 120 150 0.22 76.7 0.36 0.5 0.19 Zn.sup.4 Cocat 1 Cocat
1 Cocat 2 Cocat 2 in Poly Conc. Flow Conc. Flow polymer Rate.sup.5
Conv.sup.6 Polymer Ex. ppm lb/hr ppm lb/hr ppm lb/hr wt % wt %
Eff..sup.7 19A 4500 0.65 525 0.33 248 83.94 88.0 17.28 297 19B 4500
0.63 525 0.11 90 80.72 88.1 17.2 295 19C 4500 0.61 525 0.33 246
84.13 88.9 17.16 293 19D 4500 0.66 525 0.66 491 82.56 88.1 17.07
280 19E 4500 0.64 525 0.49 368 84.11 88.4 17.43 288 19F 4500 0.52
525 0.35 257 85.31 87.5 17.09 319 19G 4500 0.51 525 0.16 194 83.72
87.5 17.34 333 19H 4500 0.52 525 0.70 259 83.21 88.0 17.46 312 19I
4500 0.70 525 1.65 600 86.63 88.0 17.6 275 19J -- -- -- -- -- -- --
-- -- .sup.1standard cm.sup.3/min
.sup.2[N-(2,6-di(1-methylethyl)phenyl)amido)(2-isopropylphenyl)(.alpha.-n-
aphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafnium dimethyl
.sup.3bis-(1-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)imm-
ino) zirconium dimethyl .sup.4ppm in final product calculated by
mass balance .sup.5polymer production rate .sup.6weight percent
ethylene conversion in reactor .sup.7efficiency, kg polymer/g M
where g M = g Hf + g Z
TABLE-US-00009 TABLE 9A Polymer Physical Properties Heat of Tm -
CRYSTAF Density Mw Mn Fusion Tm Tc TCRYSTAF TCRYSTAF Peak Area Ex.
(g/cc) I2 I10 I10/I2 (g/mol) (g/mol) Mw/Mn (J/g) (.degree. C.)
(.degree. C.) (.degree. C.) (.degree. C.) (wt %) 19A 0.8781 0.9 0.4
6.9 123700 61000 2.0 56 119 97 46 73 40 19B 0.8749 0.9 7.3 7.8
133000 44300 3.0 52 122 100 30 92 76 19C 0.8753 5.6 38.5 6.9 81700
37300 2.2 46 122 100 30 92 8 19D 0.8770 4.7 31.5 6.7 80700 39700
2.0 52 119 97 48 72 5 19E 0.8750 4.9 33.5 6.8 81800 41700 2.0 49
121 97 36 84 12 19F 0.8652 1.1 7.5 6.8 124900 60700 2.1 27 119 88
30 89 89 19G 0.8649 0.9 6.4 7.1 135000 64800 2.1 26 120 92 30 90 90
19H 0.8654 1.0 7.0 7.1 131600 66900 2.0 26 118 88 -- -- -- 19I
0.8774 11.2 75.2 6.7 66400 33700 2.0 49 119 99 40 79 13 19J 0.8995
5.6 39.4 7.0 75500 29900 2.5 101 122 106 -- -- --
TABLE-US-00010 TABLE 9B Polymer Physical Properties of Compression
Molded Film Immediate Immediate Immediate Set after Set after Set
after Recovery Recovery Recovery Density Melt Index 100% Strain
300% Strain 500% Strain after 100% after 300% after 500% Example
(g/cm.sup.3) (g/10 min) (%) (%) (%) (%) (%) (%) 19A 0.878 0.9 15 63
131 85 79 74 19B 0.877 0.88 14 49 97 86 84 81 19F 0.865 1 -- -- 70
-- 87 86 19G 0.865 0.9 -- -- 66 -- -- 87 19H 0.865 0.92 -- 39 -- --
87 --
TABLE-US-00011 TABLE 9C Average Block Index For exemplary
polymers.sup.1 Example Zn/C.sub.2.sup.2 Average BI Polymer F 0 0
Polymer 8 0.56 0.59 Polymer 19a 1.3 0.62 Polymer 5 2.4 0.52 Polymer
19b 0.56 0.54 Polymer 19h 3.15 0.59 .sup.1Additional information
regarding the calculation of the block indices for various polymers
is disclosed in U.S. Patent Application Serial No. 11/376,835,
entitled "Ethylene/.alpha.-Olefin Block Interpolymers", filed on
Mar. 15, 2006, in the name of Colin L. P. Shan, Lonnie Hazlitt, et.
al. and assigned to Dow Global Technologies Inc., the disclose of
which is incorporated by reference herein in its entirety
.sup.2Zn/C.sub.2 * 1000 = (Zn feed flow * Zn
concentration/1000000/Mw of Zn)/(Total Ethylene feed flow * (1 -
fractional ethylene conversion rate)/Mw of Ethylene) * 1000. Please
note that "Zn" in "Zn/C.sub.2 * 1000" refers to the amount of zinc
in diethyl zinc ("DEZ") used in the polymerization process, and
"C2" refers to the amount of ethylene used in the polymerization
process.
EXAMPLES 20 AND 21
[0245] The ethylene/.alpha.-olefin interpolymer of Examples 20 and
21 were made in a substantially similar manner as Examples 19A-I
above with the polymerization conditions shown in Table 11 below.
The polymers exhibited the properties shown in Table 10. Table 10
also shows any additives to the polymer.
TABLE-US-00012 TABLE 10 Properties and Additives of Examples 20-21
Example 20 Example 21 Density (g/cc) 0.8800 0.8800 MI 1.3 1.3
Additives DI Water 100 DI Water 75 Irgafos 168 1000 Irgafos 168
1000 Irganox 1076 250 Irganox 1076 250 Irganox 1010 200 Irganox
1010 200 Chimmasorb 2020 100 Chimmasorb 2020 80 Hard segment 35%
35% split (wt %)
[0246] Irganox 1010 is
Tetrakism-methylene(3',5'-di-t-butyl-4-hydroxyhydrocinnamate)methane.
Irganox 1076 is
Octadecyl-3-(3',5'-di-t-butyl-4'-hydroxyphenyl)propionate. Irgafos
168 is Tris(2.4-di-t-butylphenyl)phosphite. Chimasorb 2020 is
1,6-Hexanediamine,
N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl)-polymer with
2,3,6-trichloro-1,3,5-triazine, reaction products with,
N-butyl-1-butanamine and
N-butyl-2,2,6-tetramethyl-4-piperidinamine.
TABLE-US-00013 TABLE 11 Polymerization Conditions for Examples
20-21 Cat Cat Cat A1.sup.2 Cat A1 B2.sup.3 B2 DEZ C.sub.2H.sub.4
C.sub.8H.sub.16 Solv. H.sub.2 T Conc. Flow Conc. Flow Conc Ex.
lb/hr lb/hr lb/hr sccm.sup.1 .degree. C. ppm lb/hr ppm lb/hr wt %
20 130.7 196.17 712.68 1767 120 499.98 1.06 298.89 0.57 4.809423 21
132.13 199.22 708.23 1572 120 462.4 1.71 298.89 0.6 4.999847
Zn.sup.4 DEZ Cocat 1 Cocat 1 Cocat 2 Cocat 2 in Poly Flow Conc.
Flow Conc. Flow polymer Rate.sup.5 Conv.sup.6 Polymer Ex. lb/hr ppm
lb/hr ppm lb/hr ppm lb/hr wt % wt % Eff..sup.7 20 0.48 5634.36 1.24
402.45 0.478 131 177 89.25 16.94 252.04 21 0.47 5706.4 1.61 289.14
1.36 129 183 89.23 17.52 188.11 *Comparative, not an example of the
invention .sup.1standard cm.sup.3/min
.sup.2[N-(2,6-di(1-methylethyl)phenyl)amido)(2-isopropylphenyl)(.alpha.-n-
aphthalen-2-diyl(6-pyridin-2-diyl)methane)]hafnium dimethyl
.sup.3bis-(1-(2-methylcyclohexyl)ethyl)(2-oxoyl-3,5-di(t-butyl)phenyl)imm-
ino) zirconium dibenzyl .sup.4ppm Zinc in final product calculated
by mass balance .sup.5polymer production rate .sup.6weight percent
ethylene conversion in reactor .sup.7efficiency, kg polymer/g M
where g M = g Hf + g Z
EXAMPLE 22
Fibers of Elastic Ethylene/.alpha.-Olefin Interpolymer and Random
Ethylene Copolymer
[0247] The elastic ethylene/.alpha.-olefin interpolymer of Example
20 was used to make monofilament fibers of 40 denier having an
approximately round cross-section. Before the fiber was made the
following additives were added to the polymer: 7000 ppm
PDMSO(polydimethyl siloxane), 3000 ppm CYANOX 1790
(1,3,5-tris-(4-t-butyl-3-hydroxy-2,6-dimethylbenzyl)-1,3,5-triazine-2,4,6-
-(1H,3H, 5H)-trione, and 3000 ppm CHIMASORB 944
Poly-[[6-(1,1,3,3-tetramethylbutyl)amino]-s-triazine-2,4-diyl][(2,2,6,6-t-
etramethyl-4-piperidyl)imino]hexamethylene[(2,2,6,6-tetramethyl-4-piperidy-
l)imino]] and 0.5% by weight TiO.sub.2.
[0248] During melt spinning, the resin was filtered using a duplex,
continuous melt filter (Kreyenborg GmbH, Model K-SWE-080). The
filter screen packs were nominal 25 .mu.m pore filtering. The
screen pack consisted of five (5) layers in the following sequence
with respect to pore size in which the flow direction was
designated from left to right: 590 micron/90 microns/25
microns/multipore non-woven/90 microns/590 microns. The five-layer
screen packs were spot-welded together to ensure optimal screen
pack alignment. The fibers were then produced using a die profile
with circular 0.8 mm diameter, a spin temperature of 299.degree.
C., a winder speed of 1000 m/minute, a spin finish of 2%, a cold
draw of 6%, and a spool weight of 150 g. The fibers were then
crosslinked using 176.4 kGy irradiation as the crosslinking agent
while maintaining the temperature of the spool below about 30 C.
These fibers are referred to as "OBC1 fiber" below.
[0249] A random copolymer having the generic name AFFINITY.TM.
KC8852G (available from The Dow Chemical Company) was used to make
monofilament fibers of 40 denier having an approximately round
cross-section. AFFINITY.TM. KC8852G is characterized by having a
melt index of 3 g/10 min., a density of 0.875 g/cm.sup.3 and
similar additives as Example 20. Before the fiber was made the
following additives were added to the polymer: 7000 ppm
PDMSO(polydimethyl siloxane), 3000 ppm CYANOX 1790
(1,3,5-tris-(4-t-butyl-3)-hydroxy-2,6-dimethylbenzyl)-1,3,5-triazine-2,4,-
6-(1H,3H,5H)-trione, and 3000 ppm CHIMASORB 944
Poly-[[6-(1,1,3,3-tetramethylbutyl)
amino]-s-triazine-2,4-diyl][2,2,6,6-tetramethyl-4-piperidyl)imino]hexamet-
hylene[(2,2,6,6-tetramethyl-4-piperidyl)imino]], 0.5% by weight
TiO.sub.2. The fibers were produced using a die profile with
circular 0.8 mm diameter, a spin temperature of 299.degree. C., a
winder speed of 1000 m/minute, a spin finish of 2%, a cold draw of
6%, and a spool weight of 150 g. The fibers were then crosslinked
using 176.4 kGy irradiation as the crosslinking agent while
maintaining the temperature of the spool below about 30 C. These
fibers are referred to as random or "RAN fiber" below.
EXAMPLE 23
Wrinkle Free Example
[0250] Two different elastic fibers were employed in this example,
OBC1 fiber made at a line speed of 650 m/min and RAN fiber made at
a winder speed of 450 m/min. These fibers are described in Example
22 above.
[0251] Five different yarns labelled as (yarns A-E below) were made
with the above fibers using conventional techniques.
[0252] Warp: Ne 40 cotton spun yarn Weft: [0253] A: DCY Ne 80/2+40D
OBC1, 2.5.times. draft for OBC1 fiber. [0254] B: DCY Ne 80/2+40D
OBC1, 3.0.times. draft for OBC1 fiber. [0255] C: DCY Ne 80/2+40D
OBC1, 3.5.times. draft for OBC1 fiber. [0256] D,E: SCY Ne40+40D
RAN, 4.0.times. draft for RAN fiber. DCY stands for "double covered
yarn." SCY or CSY stands for "ciro spun yarn"--a different
technique.
[0257] The five yarns were processed as follows using conventional
techniques: Weaving->de-sizing->mercerization->dry
cure->heat setting->sanforizing. Further process conditions
for each step are described below.
[0258] Weaving: The on loom greige construction is 120
ends/in.times.70 fills/in for all the items.
[0259] de-sizing: De-sizing at 85 C at the speed of 40 m/min.
[0260] mercerization: Mercerization at NaOH concentration at 23 Be
at the speed of 40 m/min.
[0261] dry cure and heat setting: At the 160 C by 50 m/min. Spandex
containing fabric can not go through this process. Due to: 1. Acid
environment at PH<3, 2. Spandex containing fabric required
higher than 180 C heat setting temperature.
[0262] Sanforizing: It was done at 120 C.
[0263] Wrinkle treatment: Chemical treatment was conducted at 160
C. by 50 m/min.
[0264] Fabric Description: Fabric A, B, C: 120 ends/in, 70 fills/in
in three color with different OBC1 fiber draft. Fabric D,E:120
ends/in, 70 fills/in in two pattern with 4.0.times. draft on RAN
fiber.
TABLE-US-00014 Fabric Draft Color A (DCY Ne 80/2 + 40D 2.5X Purple
OBC1, 2.5X draft for OBC1 fiber) B (DCY Ne 80/2 + 40D 3.0X Brown
OBC1, 3.0X draft for OBC1 fiber) C (DCY Ne 80/2 + 40D 3.5X Black
OBC1, 3.5X draft for OBC1 fiber) D (SCY Ne40 + 40D RAN 4.0X White
fiber) E (4.0X draft for RAN 4.0X White fiber)
Fiber composition (AATCC 20A-2004)
TABLE-US-00015 A B C D E Amount of 4.2% OBC1 4.6% 3.3% 1.6% RAN
1.3% RAN Elastic OBC1 OBC1 Polymer Cotton 95.8% 95.4% 96.7% 98.4%
98.7%
Dimensional Change After Laundering
[0265] Typical customer requirements are -3%.about.+3% shrinkage.
The fabrics containing RAN and OBC1 performed outstanding
dimensional stability by AATCC 135-2004 IVA, 12 minutes machine
wash at 120 F normal cycle, follow by tumble dry--cotton
sturdy.
TABLE-US-00016 A B C D E After Warp wise -0.1 0 -0.3 -0.3 +0.2 the
1st wash Filling wise -1.0 -0.6 -0.9 -0.4 -0.5 After Warp wise -0.7
-0.4 -0.8 -0.4 +0.2 the 3rd wash Filling wise -1.0 -0.5 -1.2 -0.3
-0.1
[0266] Therefore, after washing the amount of stretch increased
without a significant negative affect on growth.
Appearance of Fabric After Laundering
TABLE-US-00017 [0267] AATCC 124-2001 IV A (iii) A B C D E After the
1-st wash SA-4 SA-4 SA-4 SA-4 SA-4 After the 5-th wash SA-3.1
SA-3.2 SA-3.6 SA-3.1 SA-3.3
Tearing Strength
TABLE-US-00018 [0268] Typical customer minimum requirement is 1.5
LBs in both directions. ASTM D1424-1996 LBS A B C D E Tearing
Strength (lb) Warp 2.5 2.6 2.5 3.2 2.7 Filling 1.9 2.3 2.2 1.6
1.8
Stretch Properties of Fabrics
[0269] Typical customer requirements are minimum stretch ratio is
15% and growth ratio must lower than 8%.
TABLE-US-00019 ASTM D3107-1980 % A B C D E @4 lb load- Stretch 19.0
22.3 22.0 18.3 17.5 4TH Growth 4.2 5.7 5.0 3.5 3.8 85% Stretch
Growth 30 sec 10.7 6.7 8.7 6.0 6.7 @4 lb load 30 min 6.6 4.0 5.0
3.6 4.0
[0270] As seen from the data provided in the tables above, the
fabrics comprising the OBC1 ethylene o-olefin interpolymer provide
stretch fabric capable of undergoing wrinkle free treatment,
including excellent dimensional stability and stretch
properties.
EXAMPLE 24
Varying Amounts of Fiber Crosslinking
[0271] The elastic ethylene/.alpha.-olefin interpolymer of Example
20 was used to make monofilament fibers of 40 denier having an
approximately round cross-section. Before the fiber was made the
following additives were added to the polymer: 7000 ppm
PDMSO(polydimethyl siloxane), 3000 ppm CYANOX 1790
(1,3,5-tris-(4-t-butyl-3-hydroxy-2,6-dimethylbenzyl)-1,3,5-triazine-2,4,6-
-(1H,3H, 5H)-trione, and 3000 ppm CHIMASORB 944
Poly-[6-(1,1,3,3-tetramethylbutyl)amino-s-triazine-2,4-diyl][2,2,6,6-tetr-
amethyl-4-piperidyl)imino
hexamethylene[(2,2,6,6-tetramethyl-4-piperidyl)imino]] and 0.5% by
weight TiO.sub.2. The fibers were produced using a die profile with
circular 0.8 mm diameter, a spin temperature of 299.degree. C., a
winder speed of 650 m/minute, a spin finish of 2%, a cold draw of
6%, and a spool weight of 150 g. Fibers were then crosslinked using
varying amounts of irradiation from an e-beam as the crosslinking
agent.
[0272] The gel content versus the amount of irradiation is shown in
FIG. 8. The gel content was determined by weighing out an
approximately 25 mg fiber sample to 4 significant figure accuracy.
The sample is then combined with 7 ml xylene in a capped 2-dram
vial. The vial is heated 90 minutes at 125.degree. C. to
135.degree. C., with inversion mixing (i.e. turning vial upside
down) every 15 minutes, to extract essentially all the
non-crosslinked polymer. Once the vial has cooled to approximately
25.degree. C., the xylene is decanted from the gel. The gel is
rinsed in the vial with a small portion of fresh xylenes. The
rinsed gel is transferred to a tared aluminum weighing pan. The
tared dish with gel is vacuum dried at 125.degree. C. for 30
minutes to remove the xylene by evaporation. The pan with dried gel
is weighed on an analytical balance. The gel content is calculated
based on the extracted gel weight and original fiber weight. FIG. 8
shows that as the e-beam dosage increases the amount of
crosslinking (gel content) increases. One skilled in the art will
appreciate that the precise relationship between the amount of
crosslinking and e-beam dosage may be affected by a given polymer's
properties e.g., molecular weight or melt index.
EXAMPLE 25
Shirting Weight Fabrics
[0273] Shirting weight fabric was produced using the following:
Warp yarns-2.times.1 twisted, ring spun 100% Cotton yarn, count Ne
60/2. Weft yarns: weft yarns were dyed in cones prior to weaving.
Composite core spun yarn made of cotton and OBC resin based fibers
made in a similar manner as OBC1 except that a spin temperature of
295.degree. C. was employed and the fibers were crosslinked using
117.6 key irradiation as the crosslinking agent while maintaining
the temperature of the spool below about 30 C. The fibers were
about 40 denier in count, total yarn count Ne 30/1. Draft applied
to OBC elastic core was 3.3.times.. Plain weave fabric structure:
On loom density accounting for 28.7 ends/cm and 31 picks/cm, total
reed width 175 cm, total number or ends in the warp 5022.
[0274] The above fabric was processed through a finishing routine
as follows:
TABLE-US-00020 Singeing + desizing: process speed 90 m/min approx
60.degree. C. fabric temperature Scouring (7 tanks) process speed
50 m/min equipment made of 7 individual washing tanks washing
liquor temperature set at 70.degree. C.-75.degree. C.- 80.degree.
C.-85.degree. C.-90.degree. C.-90.degree. C.-90.degree. C.
(respectively for each tank) Bleaching Pad batch process Room temp
20 hour batching Scouring (6 tanks) process speed 50 m/min,
equipment made of 7 individual washing tanks washing liquor
temperature set at 90.degree. C.-95.degree. C.- 95.degree.
C.-95.degree. C.-80.degree. C.-60.degree. C. Mercerizing process
speed 50 m/min temperature 60.degree. C. Washing 95.degree.
C.-95.degree. C.-80.degree. C.-80.degree. C. Tenter frame process
speed 40 m/min, temperature 100.degree. C. Finish + tenter process
speed 50 m/min, frame 120.degree. C. Sanforizing
[0275] Finishing and tenter step include the following specific
wrinkle resistance treatment: MXL.RTM. continuous moist cross
linking process from Monforts as described at, for example,
www.Monforts.de which process comprises padding, drying at
approximately 110 C. and 30-35% steam and 5-6% residual moisture
for approximately 3 minutes, washing, and top finish final
treatment (calendaring and shrinking). The above described fabric,
after the indicated finishing process, exhibited the following
properties:
TABLE-US-00021 Property Testing Method Result Weight (g/m2): 156
Tear strength Weft [g] Marks & Spencer, P29 761 dated July 1994
Tear strength Warp [g] Marks & Spencer, P29 1522 dated July
1994 Tensile strength Weft [N] Marks & Spencer, P11 27 dated
July 1994 Tensile strength Warp [N] Marks & Spencer, P11 59
dated July 1994 Elongation [%] Dupont TTM 075 24.9 Growth [%]
Dupont TTM 077 5.8 Dimensional stability: fabric machine wash at
40.degree. C. + line 129.3 width [cm] dry Dimensional stability:
Warp machine wash at 40.degree. C. + line -0.8 shrinkage [%] dry
Dimensional stability: Weft machine wash at 40.degree. C. + line
-0.5 shrinkage [%] dry Wrinkle recovery properties: Marks &
Spencer, P134 3.5 DP rate dated September 2004 Wrinkle recovery
properties: Marks & Spencer, P22 232 crease recovery angle
[dge]
[0276] The Marks and Spencer and Dupont tests described above in
the table are incorporated herein by reference. The summaries of
the methods below are not intended to substitute for the actual
method.
[0277] Marks & Spencer, Method of test P29, Tear strength:
Method of assessing fabric tear strength using Elmendorf pendulum
tear strength tester, with maximum force exerted of 1631 g. Five
(5) fabric specimens of 80 mm.times.58 mm, previously conditioned
are prepared and tested in standard atmosphere. Tear propagates
from an initial cut in the fabric of 15 mm in length; the swinging
action of the pendulum, due to its weight and height, tears the
fabric, and tearing strength is assessed as a function of the
energy loss by the pendulum due to tearing action. The 58 mm
dimension of the specimen is: in the fabric warp direction for weft
tear strength; the tear is across the weft threads; in the fabric
weft direction for warp tear strength; the tear is across the warp
threads. The average of 5 results is reported in grams.
[0278] Marks & Spencer, Method of test P11, Tensile strength:
Method of assessing fabric tensile strength using a constant rate
of traverse tensile testing instrument, with traverse rate set at
100 mm/min, 200 mm gauge length. Three strips 300 mm long in the
direction of the test (warp or weft), frayed down to 50 mm wide are
tested, to measure the load required to break the specimen, and an
average of 3 results is reported.
[0279] DuPont method of test TTM075, Fabric Elongation (Spring
balance test). The test determines the total stretch (elongation)
of a woven fabric. Fabric specimens of known length are exercised
and the subjected to load of 6 N per cm (3.37 ld per in.). The
elongations at these loads are recorded and fabric elongation is
calculated. Fabric specimens of 33 cm.times.6 cm are cut from the
fabric to be tested; the long dimension should correspond to the
stretch direction. Specimens are raveled to 5 cm in width, than
conditioned. Two benchmarks exactly 25 cm apart are drawn.
Specimens are mounted on the spring balance apparatus, exerted 3
times with 30 N load applied for 3 seconds, then kept extended
under a load of 30 N. The length of extended specimen is compared
to the original length to calculate the elongation [%]. Individual
measurements and average are reported.
[0280] DuPont, method of test TTM077, Fabric Growth This test
determines the percentage of fabric growth in stretch wovens.
Fabrics first undergo an elongation test to determine the fabric
elongation. Specimens from these fabrics are then extended to 80%
of the fabric elongation and held in this state for 30 minutes.
They are then allowed to relax for 60 minutes, at which point the
fabric growth is measured and calculated. Three specimens are cut
for each fabric sample. Each specimen should measure 55.times.6 cm
and ravel to 5 cm in width. The long dimension should correspond
with the stretch direction. Benchmarks are drawn on each specimen
exactly 50 cm apart. Specimens are extended to 80% of maximum
elongation, kept extended 30 min and measured after 60 min
relaxation. To calculate the growth: X % Growth (L/50 cm).times.100
(where L is increase in length between the specimen after
relaxation.). The average growth for the three specimens is
reported.
[0281] Marks & Spencer, Method of test P134, Assessment of
non-iron products: To assess performance of fabrics promoted as
non-iron quality. Fabric specimens of 500 mm.times.500 mm size are
cut from the fabric, washed at 60.degree. C. and tumble dried.
Fabric appearance is than rated against standard replicas (AATCC
143).
EXAMPLE 26
Shirting Weight Fabric
[0282] Shirting weight fabric was produced using the following:
Warp yarns: Ring spun 100% Cotton yarn, count Ne 50/1. Weft yarns:
Composite core spun yarn made of cotton and OBC resin based fibers
of Example 25 above were 40 denier in count with a total yarn count
Ne 50/1. Plain weave fabric structure: On loom density accounting
for 48 ends/cm and 30 picks/cm, total reed width 175 cm, total
number or ends in the warp 8435. Such fabric was processed through
a finishing routine as follows:
TABLE-US-00022 Singeing + desizing: process speed 90 m/min approx
60.degree. C. fabric temperature Scouring (7 tanks) process speed
50 m/min equipment made of 7 individual washing tanks washing
liquor temperature set at 70.degree. C.-75.degree. C.-80.degree.
C.-85.degree. C.-90.degree. C.- 90.degree. C.-90.degree. C.
(respectively for each tank) Bleaching Pad batch process Room temp
20 hour batching Scouring (6 tanks) process speed 50 m/min,
equipment made of 7 individual washing tanks washing liquor
temperature set at 90.degree. C.-95.degree. C.- 95.degree.
C.-95.degree. C.-80.degree. C.-60.degree. C. Mercerizing process
speed 50 m/min temperature 60.degree. C. Washing 95.degree.
C.-95.degree. C.-80.degree. C.-80.degree. C. Tenter frame process
speed 40 m/min, temperature 100.degree. C. Finish + tenter frame
process speed 50 m/min, 120.degree. C. Sanforizing
[0283] Finishing and tenter step include the following specific
wrinkle resistance treatment: MXL.RTM. continuous moist cross
linking process from Monforts as described at, for example,
www.Monforts.de which process comprises padding, drying at
approximately 110 C and 30-35% steam and 5-6% residual moisture for
approximately 3 minutes, washing, and top finish final treatment
(calendaring and shrinking). The above described fabric, after the
indicated finishing process, exhibited the following
properties:
TABLE-US-00023 Property Testing Method Result Weight (g/m2): 113
Tear strength Weft [g] Marks & Spencer P29 587 dated July 1994
Tear strength Warp [g] Marks & Spencer P29 1000 dated July 1994
Tensile strength Weft [N] Marks & Spencer P11 14 dated July
1994 Tensile strength Warp [N] Marks & Spencer P11 57 dated
July 1994 Elongation [%] Dupont TTM 075 12 Growth [%] Dupont TTM
077 4.2 Dimensional stability: fabric machine wash at 40.degree. C.
+ line 138.9 width [cm] dry Dimensional stability: Warp machine
wash at 40.degree. C. + line -1 shrinkage [%] dry Dimensional
stability: Weft machine wash at 40.degree. C. + line -0.5 shrinkage
[%] dry Wrinkle recovery properties: Marks & Spencer P134 3.1
DP rate dated September 2004 Wrinkle recovery properties: Marks
& Spencer P22 236 crease recovery angle [dge]
EXAMPLE 27
Shirting Weight Fabric
[0284] Shirting weight fabric was produced using the following:
Warp yarns: Ring spun 100% Cotton yarn, count Ne 50/1 Weft yarns:
weft yarns were dyed in cones prior to weaving. Composite core spun
yarn made of cotton and OBC resin based fibers of Example 25 40
denier in count, and a total yarn count Ne 50/1. Plain weave fabric
structure: On loom density accounting for 48 ends/cm and 30
picks/cm, total reed width 175 cm, total number or ends in the warp
8435 (same as per example 26). The fabric was processed through a
finishing routine as follows:
TABLE-US-00024 Singeing + desizing: process speed 90 m/min approx
60.degree. C. fabric temperature Scouring (7 tanks) process speed
50 m/min equipment made of 7 individual washing tanks washing
liquor temperature set at 70.degree. C.-75.degree. C.-80.degree.
C.-85.degree. C.-90.degree. C.- 90.degree. C.-90.degree. C.
(respectively for each tank) Bleaching Pad batch process Room temp
20 hour batching Scouring (6 tanks) process speed 50 m/min,
equipment made of 7 individual washing tanks washing liquor
temperature set at 90.degree. C.-95.degree. C.- 95.degree.
C.-95.degree. C.-80.degree. C.-60.degree. C. Mercerizing process
speed 50 m/min temperature 60.degree. C. Washing 95.degree.
C.-95.degree. C.-80.degree. C.-80.degree. C. Tenter frame process
speed 40 m/min, temperature 100.degree. C. Finish + tenter frame
process speed 50 m/min, 120.degree. C. Sanforizing
[0285] Finishing and tenter step include the following specific
wrinkle resistance treatment: MXL.RTM. continuous moist cross
linking process from Monforts as described at, for example,
www.Monforts.de which process comprises padding, drying at
approximately 110 C and 30-35% steam and 5-6% residual moisture for
approximately 3 minutes, washing, and top finish final treatment
(calendaring and shrinking). The above described fabric, after the
indicated finishing process, exhibited the following
properties:
TABLE-US-00025 Property Testing Method Result Weight (g/m2): 111
Tear strength Weft [g] Marks & Spencer P29 543 dated July 1994
Tear strength Warp [g] Marks & Spencer P29 1156 dated July 1994
Tensile strength Weft [N] Marks & Spencer P11 15 dated July
1994 Tensile strength Warp [N] Marks & Spencer P11 55 dated
July 1994 Elongation [%] Dupont TTM 075 13.6 Growth [%] Dupont TTM
077 2.3 Dimensional stability: fabric Cmachine wash at 40.degree.
C. + line 145.7 width [cm] dry Dimensional stability: Warp machine
wash at 40.degree. C. + line -0.5 shrinkage [%] dry Dimensional
stability: Weft machine wash at 40.degree. C. + line -0.5 shrinkage
[%] dry Wrinkle recovery properties: Marks & Spencer P134 3 DP
rate dated September 2004 Wrinkle recovery properties: Marks &
Spencer P22 259.5 crease recovery angle [dge]
EXAMPLE 28
Shirting Weight Fabric
[0286] Shirting weight fabric was produced using the following:
Warp yarns: Ring spun 100% Cotton yarn, count Ne 50/1. Weft yarns:
(inserted in alternating picks) (1) Composite core spun yarn made
of cotton and OBC resin based fibers of Example 25 40 denier in
count and a total yarn count Ne 50/1 and (2) Ring spun 100% Cotton
yarn, count Ne 50/1. Plain weave fabric structure: On loom density
accounting for 48 ends/cm and 30 picks/cm, total reed width 175 cm,
total number or ends in the warp 8435. Such fabric was processed
through a finishing routine as follows:
TABLE-US-00026 Singeing + desizing: process speed 90 m/min approx
60.degree. C. fabric temperature Scouring (7 tanks) process speed
50 m/min equipment made of 7 individual washing tanks washing
liquor temperature set at 70.degree. C.-75.degree. C.-80.degree.
C.-85.degree. C.-90.degree. C.- 90.degree. C.-90.degree. C.
(respectively for each tank) Bleaching Pad batch process Room temp
20 hour batching Scouring (6 tanks) process speed 50 m/min,
equipment made of 7 individual washing tanks washing liquor
temperature set at 90.degree. C.-95.degree. C.- 95.degree.
C.-95.degree. C.-80.degree. C.-60.degree. C. Mercerizing process
speed 50 m/min temperature 60.degree. C. Washing 95.degree.
C.-95.degree. C.-80.degree. C.-80.degree. C. Tenter frame process
speed 40 m/min, temperature 100.degree. C. Finish + tenter frame
process speed 50 m/min, 120.degree. C. Sanforizing
[0287] Finishing and tenter step include the following specific
wrinkle resistance treatment MXL.RTM. continuous moist cross
linking process from Monforts as described at, for example,
www.Monforts.de which process comprises padding, drying at
approximately 110 C and 30-35% steam and 5-6% residual moisture for
approximately 3 minutes washing, and top finish final treatment
(calendaring and shrinking). The above described fabric, after the
indicated finishing process, exhibited the following
properties:
TABLE-US-00027 Property Testing Method Result Weight (g/m2): 113
Tear strength Weft [g] Marks & Spencer P29 608 dated July 1994
Tear strength Warp [g] Marks & Spencer P29 1283 dated July 1994
Tensile strength Weft [N] Marks & Spencer P11 14 dated July
1994 Tensile strength Warp [N] Marks & Spencer P11 53 dated
July 1994 Elongation [%] Dupont TTM 075 14.9 Growth [%] Dupont TTM
077 3.5 Dimensional stability: fabric machine wash at 40.degree. C.
+ line 143.8 width [cm] dry Dimensional stability: Warp machine
wash at 40.degree. C. + line -0.8 shrinkage [%] dry Dimensional
stability: Weft machine wash at 40.degree. C. + line -0.5 shrinkage
[%] dry Wrinkle recovery properties: Marks & Spencer P134 3.4
DP rate dated September 2004 Wrinkle recovery properties: Marks
& Spencer P22 247 crease recovery angle [dge]
EXAMPLE 29
Shirting Weight Fabric
[0288] Shining weight fabric was produced using the following:
Warp yarns: Ring spun 100% Cotton yarn, count Ne 50/1. Weft yarns:
well yarns were dyed in cones prior to weaving (inserted in
alternating picks) (1) Composite core spun yarn made of cotton and
OBC resin based fibers of Example 25 40 denier in count and total
yarn count Ne 50/1 and (2) Ring spun 100% Cotton yarn, count Ne
50/1. Plain weave fabric structure: On loom density accounting for
48 ends/cm and 30 picks/cm, total reed width 175 cm, total number
or ends in the warp 8435 (same as per example 28). Such fabric was
processed through a finishing routine as follows:
TABLE-US-00028 Singeing + desizing: process speed 90 m/min approx
60.degree. C. fabric temperature Scouring (7 tanks) process speed
50 m/min equipment made of 7 individual washing tanks washing
liquor temperature set at 70.degree. C.-75.degree. C.-80.degree.
C.-85.degree. C.-90.degree. C.- 90.degree. C.-90.degree. C.
(respectively for each tank) Bleaching Pad batch process Room temp
20 hour batching Scouring (6 tanks) process speed 50 m/min,
equipment made of 7 individual washing tanks washing liquor
temperature set at 90.degree. C.-95.degree. C.- 95.degree.
C.-95.degree. C.-80.degree. C.-60.degree. C. Mercerizing process
speed 50 m/min temperature 60.degree. C. Washing 95.degree.
C.-95.degree. C.-80.degree. C.-80.degree. C. Tenter frame process
speed 40 m/min, temperature 100.degree. C. Finish + tenter frame
process speed 50 m/min, 120.degree. C. Sanforizing
[0289] Finishing and tenter step include the following specific
wrinkle resistance treatment: MXL.RTM. continuous moist cross
linking process from Monforts as described at, for example,
www.Monforts.de which process comprises padding, drying at
approximately 110 C and 30-35% steam and 5-6% residual moisture for
approximately 3 minutes, washing, and top finish final treatment
(calendaring and shrinking). The above described fabric, after the
indicated finishing process, exhibited the following
properties:
TABLE-US-00029 Property Testing Method Result Weight (g/m2): 111
Tear strength Weft [g] Marks & Spencer P29 521 dated July 1994
Tear strength Warp [g] Marks & Spencer P29 978 dated July 1994
Tensile strength Weft [N] Marks & Spencer P11 16 dated July
1994 Tensile strength Warp [N] Marks & Spencer P11 53 dated
July 1994 Elongation [%] Dupont TTM 075 16 Growth [%] Dupont TTM
077 2.7 Dimensional stability: fabric machine wash at 40.degree. C.
+ line 147.3 width [cm] dry Dimensional stability: Warp machine
wash at 40.degree. C. + line -0.8 shrinkage [%] dry Dimensional
stability: Weft machine wash at 40.degree. C. + line -0.5 shrinkage
[%] dry Wrinkle recovery properties: Marks & Spencer P134 3.1
DP rate dated September 2004 Wrinkle recovery properties: Marks
& Spencer P22 257 crease recovery angle [deg]
EXAMPLE 30
Shirting Weight Fabric
[0290] Shining weight fabric was produced using the following:
[0291] Warp yarns: Ring spun 100% Cotton yarn count Ne 40/1. [0292]
Weft yarns: Composite core spun yarn made of cotton and OBC resin
based fibers of Example 25 of 40 denier in count and total yarn
count Ne 40/1. [0293] Plain weave fabric structure: On loom density
accounting for 50 ends/cm and 24 picks/cm, total reed width 170 cm,
total number of ends in the warp 8501.
[0294] Such fabric was processed through a finishing routine as
follows:
TABLE-US-00030 Singeing + desizing: process speed 90 m/min approx
60.degree. C. fabric temperature Scouring (7 tanks) process speed
50 m/min equipment made of 7 individual washing tanks washing
liquor temperature set at 70.degree. C.-75.degree. C.-80.degree.
C.-85.degree. C.-90.degree. C.- 90.degree. C.-90.degree. C.
(respectively for each tank) Bleaching Pad batch process Room temp
20 hour batching Scouring (6 tanks) process speed 50 m/min,
equipment made of 7 individual washing tanks washing liquor
temperature set at 90.degree. C.-95.degree. C.- 95.degree.
C.-95.degree. C.-80.degree. C.-60.degree. C. Mercerizing process
speed 50 m/min temperature 60.degree. C. Washing 95.degree.
C.-95.degree. C.-80.degree. C.-80.degree. C. Tenter frame process
speed 40 m/min, temperature 100.degree. C. Finish + tenter frame
process speed 50 m/min, 120.degree. C. Sanforizing
[0295] Finishing and tenter step include the following specific
wrinkle resistance treatment: MXL.RTM. continuous moist cross
linking process from Monforts as described at, for example,
www.Monforts.de which process comprises padding, drying at
approximately 110 C and 30-35% steam and 5-6% residual moisture for
approximately 3 minutes, washing, and top finish final treatment
(calendaring and shrinking). The above described fabric, after the
indicated finishing process, exhibited the following
properties:
TABLE-US-00031 Property Testing Method Result Weight (g/m2): 132
Tear strength Weft [g] Marks & Spencer P29 761 dated July 1994
Tear strength Warp [g] Marks & Spencer P29 1326 dated July 1994
Tensile strength Weft [N] Marks & Spencer P11 14 dated July
1994 Tenslie strength Warp [N] Marks & Spencer P11 68 dated
July 1994 Elongation [%] Dupont TTM 075 12.6 Growth [%] Dupont TTM
077 4.2 Dimensional stability: fabric machine wash at 40.degree. C.
+ line 145.7 width [cm] dry Dimensional stability: Warp machine
wash at 40.degree. C. + line -1 shrinkage [%] dry Dimensional
stability: Weft machine wash at 40.degree. C. + line -0.5 shrinkage
[%] dry Wrinkle recovery properties: Marks & Spencer P134 3.1
DP rate dated September 2004 Wrinkle recovery properties: Marks
& Spencer P22 220 crease recovery angle [deg]
EXAMPLE 31
Shirting Weight Fabric
[0296] Shirting weight fabric was produced using the following:
Warp yarns: Ring spun 100% Cotton yarn count Ne 40/1 Weft yarns:
weft yarns were dyed in cones prior to weaving. Composite core spun
yarn made of cotton and OBC resin based fibers of Example 25 of 40
denier in count and total yarn count Ne 40/1. Plain weave fabric
structure: On loom density accounting for 50 ends/cm and 24
picks/cm, total reed width 170 cm, total number of ends in the warp
8501. Such fabric was processed through a finishing routine as
follows:
TABLE-US-00032 Singeing + desizing: process speed 90 m/min approx
60.degree. C. fabric temperature Scouring (7 tanks) process speed
50 m/min equipment made of 7 individual washing tanks washing
liquor temperature set at 70.degree. C.-75.degree. C.-80.degree.
C.-85.degree. C.-90.degree. C.- 90.degree. C.-90.degree. C.
(respectively for each tank) Bleaching Pad batch process Room temp
20 hour batching Scouring (6 tanks) process speed 50 m/min,
equipment made of 7 individual washing tanks washing liquor
temperature set at 90.degree. C.-95.degree. C.- 95.degree.
C.-95.degree. C.-80.degree. C.-60.degree. C. Mercerizing process
speed 50 m/min temperature 60.degree. C. Washing 95.degree.
C.-95.degree. C.-80.degree. C.-80.degree. C. Tenter frame process
speed 40 m/min, temperature 100.degree. C. Finish + tenter frame
process speed 50 m/min, 120.degree. C. Sanforizing
[0297] Finishing and tenter step include the following specific
wrinkle resistance treatment: MXL.RTM. continuous moist cross
linking process from Monforts as described at, for example,
www.Monforts.de which process comprises padding, drying at
approximately 110 C and 30-35% steam and 5-6% residual moisture for
approximately 3 minutes, washing and top finish final treatment
(calendaring and shrinking). The above described fabric, after the
indicated finishing process, exhibited the following
properties:
TABLE-US-00033 Property Testing Method Result Weight (g/m2): 130
Tear strength Weft [g] Marks & Spencer P29 565 dated July 1994
Tear strength Warp [g] Marks & Spencer P29 1174 dated July 1994
Tensile strength Weft [N] Marks & Spencer P11 14 dated July
1994 Tensile strength Warp [N] Marks & Spencer P11 64 dated
July 1994 Elongation [%] Dupont TTM 075 9.2 Growth [%] Dupont TTM
077 2.8 Dimensional stability: fabric machine wash at 40.degree. C.
+ line 150 width [cm] dry Dimensional stability: Warp machine wash
at 40.degree. C. + line -0.8 shrinkage [%] dry Dimensional
stability: Weft machine wash at 40.degree. C. + line -0.5 shrinkage
[%] dry Wrinkle recovery properties: Marks & Spencer P134 3.0
DP rate dated September 2004 Wrinkle recovery properties: Marks
& Spencer P22 242 crease recovery angle [deg]
* * * * *
References